SYSTEMS AND METHODS FOR SENSING ABNORMAL FAN OPERATION VIA COMPRESSOR SUCTION SENSOR

BACKGROUND

The present application relates generally to the field of climate control systems. More specifically, the present disclosure relates to systems, methods, and devices for detecting an obstruction in an airflow circuit thereof.

SUMMARY

One embodiment of the disclosure is a climate control system that includes a fluidic circuit. The fluidic circuit includes a compressor fluidly coupled to a condenser and an evaporator. The fluidic circuit includes a metering device intermediate to the condenser and the evaporator, the compressor and the metering device disposed at opposite ends of each of a high pressure portion of the fluidic circuit, and a low pressure portion of the fluidic circuit. The climate control system includes a sensor configured to detect a plurality of data points associated with the fluidic circuit. The climate control system includes a controller. The controller can store the plurality of data points associated with the fluidic circuit and a time associated with each of the data points. The controller can detect a plurality of deviations between the data points, each deviation comprising a magnitude and a temporal sequence. The controller can compare each of the plurality of deviations to a predefined threshold. The controller can determine, based on the comparison of the deviations to the predefined threshold, a condition indicative of an obstruction of an air flow circuit of the climate control system.

Another embodiment of the present disclosure is a method. The method can be performed by a controller. The method includes receiving, by a controller, from a sensor, a plurality of data points associated with a fluidic circuit, the fluidic circuit including a compressor fluidly coupled to a condenser and an evaporator and a metering device intermediate to the condenser and the evaporator. The method includes storing, by the controller, the plurality of data points associated with the fluidic circuit and a time associated with each of the data points. The method includes detecting, by the controller, a plurality of deviations between the data points, each deviation comprising a magnitude and a temporal sequence. The method includes comparing, by the controller, each of the plurality of deviations to a predefined threshold. The method includes determining, by the controller and based on the comparison of the deviations to the predefined threshold, a condition indicative of an obstruction of an air flow. The compressor and the metering device can be at opposite ends of each of a high pressure portion of the fluidic circuit, and a low pressure portion of the fluidic circuit.

Yet another embodiment of the present disclosure is a non-transitory computer-readable media. The media includes instruction to receive, from a sensor, a plurality of data points associated with a fluidic circuit. The media includes instruction to store the plurality of data points associated with the fluidic circuit and a time associated with each of the data points. The media includes instruction to detect a plurality of deviations between the data points, each deviation comprising a magnitude and a temporal sequence. The media includes instruction to compare each of the plurality of deviations to a predefined threshold. The media includes instruction to determine, based on the comparison of the deviations to the predefined threshold, a condition indicative of an obstruction of an air flow circuit of the climate control system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a dehumidifier, according to an embodiment of the present disclosure.

FIG. 2 is a pictorial circuit diagram of a dehumidifier, according to an embodiment of the present disclosure.

FIG. 3 is a time-temperature diagram of a response to an airflow obstruction of a dehumidifier, according to an embodiment of the present disclosure.

FIG. 4 is a time-temperature diagram of a defrost cycle of a dehumidifier, according to an embodiment of the present disclosure.

FIG. 5 is a method of detecting an air flow obstruction in a dehumidifier, according to an embodiment of the present disclosure.

FIG. 6 is a method of detecting an air flow obstruction in a dehumidifier, according to an embodiment of the present disclosure.

FIG. 7 is a method of detecting an air flow obstruction in a climate control system, according to an embodiment of the present disclosure.

FIG. 8 is a block diagram illustrating an architecture for a computer system that can be employed to implement elements of the systems and methods described and illustrated herein.

DETAILED DESCRIPTION

Various climate control systems, including heat pumps, dehumidifiers, air conditioning systems, other refrigeration systems, and the like, employ a refrigerant in a fluidic circuit to convey thermal energy between an evaporator and a condenser. The systems may include an air flow circuit to increase a rate of heat exchange with an environment. For example, a dehumidifier can employ one or more fans to promote heat exchange between a condenser unit or an evaporator unit, and an ambient environment. Some climate control systems can include filters such as high efficiency particular air (HEPA) filters, grills, mesh filters, or the like in an airflow circuit. The filters or other portions of the airflow circuit can become clogged, damaged, or otherwise obstructed. Further, fans can fail, evaporators can ice over, and so on. Such conditions may reduce a performance of or cause damage to the climate control system.

In general, disclosed herein are systems for managing climate control systems such as dehumidifiers. A controller can receive a refrigerant profile, such that upon receipt of a temperature or pressure from a sensor, the other of the temperature or pressure may be inferred at a same point in the refrigerant circuit. The controller can receive measurements from the sensors sequenced over time, and infer a condition of the climate control system therefrom. For example, the controller can receive a measurement of a temperature or a pressure from a dehumidifier in an expected or stable range prior to an obstruction. The controller can detect a decrease in temperature incident to a drop in the airflow, and a subsequent rise in temperature incident to an increase in condenser temperature as the airflow fails to exchange heat between the condenser and the environment. The controller can detect the obstruction based on the longitudinal temperature measurements or pressure profile of the compressor by detecting the initial decrease and subsequent increase in temperature. Responsive to the detection of the obstruction, the climate control system can provide an indication of the condition (e.g., illuminate an LED or alert tone of the user interface), or adjust the operation of the climate control system (e.g., reduce power to the compressor).

FIG. 1 is a block diagram of a dehumidifier 100, according to an embodiment of the present disclosure. The dehumidifier 100 can include a controller 102, a pressure or temperature sensor 104, a fluidic circuit 106, an air flow circuit 108, a user interface 110, and a data repository 120. The controller 102 can include at least one processing unit or other logic device such as a programmable logic array engine, or module configured to communicate with the data repository 120 or database, or interface with various software stored on a memory thereof. The controller 102, pressure or temperature sensor 104, fluidic circuit 106, air flow circuit 108, or user interface 110 can be separate components, a single component, or part of the dehumidifier 100. The dehumidifier 100 can include hardware elements, such as one or more processors, logic devices, or circuits. For example, the dehumidifier 100 can include one or more components or structures of functionality of computing devices depicted in FIG. 8.

FIG. 1, like the other figures described herein, is not intended to be limiting. Indeed, the systems and methods of this disclosure can be applied to various applications. For example, although the present figure refers to a dehumidifier 100, the systems and methods herein can be employed to operate heat pumps, refrigerators, air conditioners, and so forth.

The data repository 120 can include one or more local or distributed databases, and can include a database management system. The data repository 120 can include computer data storage or memory and can store one or more of a refrigerant profile 122, flow restriction profile 124, or temporally sequenced sensor data 126. The refrigerant profile 122 can refer to a temperature curve over time, which can be represented or expressed by a series of measurements over time. The refrigerant profile 122 can include a pressure temperature relationship or pressure-temperature-state relationship of a refrigerant of the dehumidifier 100. A refrigerant refers to a fluid which undergoes a state change in the fluidic circuit 106 (e.g., condenses in the condenser and evaporates in the evaporator). The controller 102 can employ the refrigerant profile to determine a pressure correlated with a sensed pressure or a pressure associated with the sensed temperature. The refrigerant profile 122 can be a property of the refrigerant fluid or can include attributes of other device components. For example, the refrigerant profile 122 can include a relationship between a condition of a humidifier (e.g., a failed fan or obstructed filter) and a temperature increase upon an increased flow rate from a high side pressure line to a low side pressure line (e.g., via a metering device). The flow restriction profile 124 can include one or more thresholds indicative of a condition of the airflow circuit of the dehumidifier 100. For example, the flow restriction profile 124 can include an upper or lower threshold or a reference response curve to a condition. The temporally sequenced sensor data 126 can include data points taken sequentially over time such that the sensor data 126 corresponds to the response of the dehumidifier 100 prior to, during, or subsequent to an obstruction, such as during an initial and subsequent response to the obstruction. References to temporally sequenced sensor data 126 or data points does not imply any particular sequence.

The dehumidifier 100 can include, interface with, or otherwise utilize at least one controller 102. The controller 102 can include or interface with one or more processors and memory. The processor can be implemented as a specific purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable electronic processing components. The processors and memory can be implemented using one or more devices, such as devices in a client-server implementation. The memory can include one or more devices (e.g., random access memory (RAM), read-only memory (ROM), flash memory, hard disk storage) for storing data and computer code for completing and facilitating the various user or client processes, layers, and modules. The memory can be or include volatile memory or non-volatile memory and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures of the inventive concepts disclosed herein. The memory can be communicably connected to the processor and include computer code or instruction modules for executing one or more processes described herein. The memory can include various circuits, software engines, and/or modules that cause the processor to execute the systems and methods described herein, such as to cause the communication or processing of audio signals.

The controller 102 can include or be coupled with communications electronics. The communications electronics can conduct wired and/or wireless communications. For example, the communications electronics can include one or more wired (e.g., Ethernet, PCIe, or AXI) or wireless transceivers (e.g., a Wi-Fi transceiver, a Bluetooth transceiver, a NFC transceiver, or a cellular transceiver). The controller 102 may be in network communication or otherwise communicatively coupled with the sensor 104, user interface 110, or other components of the dehumidifier 100. The controller 102 can cause one or more operations disclosed, such as by employing another element of the data processing system. For example, operations disclosed by other elements of the data processing system may be initiated, scheduled, or otherwise managed by the controller 102.

The dehumidifier 100 can include at least one sensor 104 designed, constructed, or operational to generate data points associated with the fluidic circuit 106. For example, the sensor 104 can be a temperature sensor 104 or a pressure sensor 104. The sensor 104 can be coupled with or contained within a fluidic circuit 106 to detect a pressure or temperature of a fluid (e.g., liquid, gas, or vapor). The sensor 104 can detect an absolute pressure or temperature, a pressure or temperature relative to an ambient environment, or a pressure or temperature relative to another portion of the fluidic circuit 106. For example, the sensor 104 can be a single sensor 104 indicative of a temperature (e.g., a frost sensor 104, suction sensor 104, or evaporator temperature sensor 104). The sensor 104 can detect a temperature (e.g., a low temperature condition) in a first portion of the dehumidifier 100 (e.g., at the suction side of the dehumidifier 100) indicative of a condition (e.g., temperature, pressure, or the like) of another portion (e.g., a high pressure side of the evaporator) according to a profile, such that a sensor in the high pressure side may be omitted.

According to some embodiments, the sensor 104 (e.g., a pressure sensor 104) can traverse a boundary between different portions of the fluidic circuit 106 or a portion of the fluidic circuit 106 and an ambient environment. A junction between the portions of the sensor 104 can include a hermetically sealed wall (e.g., gaskets, o-rings, or the like) which may increase a number of failure modes of the sensor 104 or the system generally (e.g., refrigerant leaks). In some embodiments, a sensor 104 can monitor a temperature of pressure associated with the evaporator, such as the evaporator outlet or inlet, or a body thereof. For example, the sensor can detect a condition of a fluid in a gaseous, vaporous, or liquid state.

The dehumidifier 100 can include at least one fluidic circuit 106 designed, constructed, or operational to cycle a refrigerant there through to transfer heat between portions of the dehumidifier 100. The fluidic circuit 106 can include various devices connected by lines such as copper tube for air-conditioning and refrigeration (ACR), polymers, copper iron alloys, carbon steel, stainless steel, and the like. The fluidic circuit 106 can include a compressor to pressurize the circuit, a condenser to generate or exhaust heat from the system, such as to convey heat to an ambient environment. The fluidic circuit 106 can include an evaporator to absorb heat from an ambient environment, which may cause condensation to form about or proximal to the evaporator (e.g., wherein the dew point of the ambient environment exceeds to the temperature of the evaporator). The fluidic circuit 106 can include one or more valves, nozzles, or the like to adjust or arrest a flow of a fluid through the fluidic circuit 106. Elements of the fluidic circuit 106 are further described with regard to FIG. 2, which depicts the fluidic circuit 106 along a loop, which may vary from the mechanical assembly of the humidifier.

The dehumidifier 100 can include at least one air flow circuit 108 designed, constructed, or operational to pass air from an ambient environment over elements of the dehumidifier 100 to exchange heat or moisture therebetween. For example, the air flow circuit 108 can include fans, electro-static air movers, or micro-blowers. The air flow circuit 108 can include air inlets or exhausts in a body or chassis of the dehumidifier 100 (e.g., grills, vents, mesh facings, etc.). The air flow circuit 108 can include a filter such as a fiberglass filter, pleated media filter, or HEPA filter. The air flow circuit 108 can include a passage through or over the condenser, evaporator, or other components of the dehumidifier 100. The air flow circuit 108 can include a single, substantially linear path through the condenser, evaporator, or filter (e.g., perpendicular to a largest surface area facing of the various components) or include one or more remote devices. For example, an air flow circuit 108 of a heat pump can employ a fan to increase a rate of heat exchange between a condenser unit and an ambient environment, and a different fan to increase a rate of heat exchange between an evaporator unit and a conditioned environment. The air flow circuit 108 can be an open loop circuit, such that air exhaust therefrom may not be contained within the circuit (e.g., may include one or more open loops).

According to various conditions of the dehumidifier 100 or a surrounding environment, an obstruction to air flow through the dehumidifier 100 may arise. Such a condition can arise gradually or precipitously. For example, the filter can accumulate dust, debris, or other particulate matter gradually over a service life of the filter, or debris such as plastic wrap can block the filter, an inlet vent, or an evaporator or condenser. The fan can fail according to a gradual reduction in a fluid pressure, or an abrupt failure, (e.g., a mechanical or electrical failure).

Airflow can maintain the operation of various components of the dehumidifier. For example, air flow can pass over the evaporator whereupon the air temperature drops below a dew point, condensing water vapor from the air. The air flow may continue to pass over the condenser, which may return thermal energy to the air. The airflow can pass over a one or more filter elements to remove particulates therefrom, and one or more fans to maintain the velocity of the flow. An interruption to airflow can cause a corresponding reduction to an operation of the condenser and evaporator The effects of such a reduction can vary according to the amount of change and the rate of change of the airflow, as is further described with regard to FIG. 2.

The dehumidifier 100 can include at least one user interface 110 designed, constructed, or operational to interface with a user. For example, the user interface 110 can include a visual indicator such as a light emitting diode (LED), liquid crystal display (LCD), or the like. The user interface 110 can include an audible indicator such as a buzzer, speaker, etc. The user interface 110 can include an audio output device such as a network interface to connect to another device via private or public network (e.g., Bluetooth, Zigbee, or the Internet). The user interface 110 can convey an indication of a status of the dehumidifier 100, or a user action, such as an indication to replace a filter, verify if the filter is clogged, verify whether a fan is operational, etc. The user interface 110 may receive an input such as an indication to resume operation following a detected condition, pausing or halting an alert, or indicating that an action has been taken (e.g., replacing or checking a filter). The user interface 110 can alternate or sequence through various indications or alerts. For example, responsive to a detection of a loss of airflow, the user interface 110 may alternatively provide indications to check a status of a fan, filter, or inlet valve. For example, the user interface 110 can present conditions indicative of the loss of air flow according to a frequency of occurrence, an ease of inspection, or another sequence.

FIG. 2 is a pictorial circuit diagram of a dehumidifier 100, according to an embodiment of the present disclosure. For example, the dehumidifier can include a fluidic circuit 106 to convey a refrigerant there through. The fluidic circuit 106 includes a compressor 202 having a (high pressure side) outlet coupled to an inlet of a condenser 206. The condenser 206 has an outlet coupled to an input of a metering device 218. The metering device 218 has an outlet coupled to an evaporator 208 which is, in turn, coupled to the (low pressure/suction side) inlet of the compressor 202. Put differently, the condenser 206 and evaporator 208 can be coupled to opposite ends of the metering device 218.

During operation, a hydraulic, mechanical, or electrical source 204 can provide power to the compressor 202, such that the refrigerant, at the outlet of the compressor 202, can exceed a pressure and temperature of the refrigerant at the inlet to the compressor 202 (e.g., is a first high pressure portion 214 of the fluidic circuit 106). As depicted, a sensor 104 (e.g., a pressure sensor 104) can monitor a pressure of the first high pressure portion 214 of the fluidic circuit 106 to prevent an over pressurization of the condenser 206, which may be indicative or overheating, over-pressure, or another condition which can impede an operation or integrity of the dehumidifier. However, the sensor 104 can increase a complexity of the dehumidifier 100, particularly so for embodiments traversing a boundary of the fluidic circuit 106 (e.g., a pressure sensor coupling may increase a likelihood of refrigerant leaks). According to some embodiments of the present disclosure, such a sensor 104 may be omitted, which may reduce a number of failure modes. For example, the state of the high pressure portions of the fluidic circuit can be inferred based on a sensor in a low pressure portion, by an evaluation of temporally sequenced sensor data 126.

The fluid exhausted by the compressor 202 can be a gas or vapor phase of the refrigerant. The refrigerant can pass through the condenser 206 (which may also be referred to as a condenser coil), which may cause the refrigerant to condense into a liquid phase. For example, the dew point of the refrigerant may exceed an ambient temperature surrounding the condenser 206. A fan 212 (or other air moving device) can increase a flow of ambient air over the condenser 206 which may maintain the ambient temperature along an outer surface of the condenser 206. The fan 212 may direct the airflow through a filter 210 to maintain air quality (e.g., remove particulate matter). An obstruction of the filter 210 or other reduction of air flow (e.g., a failed fan 212) may prevent the condenser 206 from condensing the refrigerant. For example, the condenser 206 may heat an envelope of ambient air around the condenser 206 to a temperature in excess of the dew point of the refrigerant. Such a loss of airflow can lead to an increase in temperature/pressure of the high pressure portion of the fluidic circuit 106. The increase temperature/pressure may lead to an ingress of overheated/overpressure refrigerant to the low pressure portions, as is described henceforth.

The outlet of the condenser 206 can include condensed refrigerant, which may be lower temperature than the inlet fluid (e.g., according to heat exchanged with the ambient air to condense said refrigerant). The fluidic circuit 106 (e.g., a second high pressure portion 216) can extend between the outlet of the condenser 206 and a metering device 218. The metering device 218 (e.g., expansion valve) can selectively pass low pressure refrigerant (e.g., liquid refrigerant), via a first low pressure portion 220 of the fluidic circuit 106, to an inlet of the evaporator 208. A fan 212 can pass ambient air over the evaporator 208. The temperature of the ambient air may exceed the evaporation temperature of the refrigerant, causing said refrigerant to evaporate, and any water vapor in the ambient air to condense (e.g., to lower a moisture content of the air). The outlet of the evaporator 208 may be referred to as a second low pressure portion 222 of the fluidic circuit 106.

Upon a loss of airflow to the condenser and evaporator, the temperature differential between the cooler refrigerant in the evaporator 208 and the warmer ambient air may drop, which may decrease an evaporation of the refrigerant within the evaporator 208. Thus, the pressure of the low pressure portions 220, 222 may decrease. Contemporaneously, as discussed above, the temperature of the condenser 206 may increase. For example, an obstruction can simultaneously cause a loss of airflow over each of the condenser 206 and the evaporator 208. As the temperature and pressure of the first 214 and second high pressure portions 216 rise, they may transfer energy (e.g., via thermal radiation or passage of the fluid via the metering device 218). Such transfer can increase the pressure of the low pressure portions 220, 222. A sensor 104 monitoring at any of the first low pressure portion 220, the second low pressure portion 222, or the evaporator can detect a temperature or pressure thereof. For example, the sensor 104 can measure a data point (e.g., a temperature or pressure) at an operating temperature prior to an airflow obstruction, measure a data point subsequent to the decrease in evaporation indicating a decrease in temperature or pressure, and another data point subsequent to the ingress of the high temperature refrigerant into the low pressure lines indicative of the corresponding rise of the temperature.

A controller 102 can receive each of the data points, and determine that a drop in airflow has occurred. In some embodiments, the controller 102 can distinguish various drops in airflow such as a portion of airflow obstructed, or by the relative time or magnitudes between the data points. For example, the controller 102 can determine a drop in airflow associated with an iced-over evaporator 208, a fan failure, an obstruction, or so forth. The controller 102 can be operably coupled to various devices of the dehumidifier 100. For example, the controller 102 can be operatively coupled to the compressor, via a compressor power switch 224, and may cause an interruption in the operation of the compressor 202 by removing power supplied thereto. In some embodiments, the compressor power switch 224 can include various power settings such that the controller 102 can cause a reduction of power supplied to the compressor 202, responsive to a detected obstruction (e.g., a partial obstruction). The controller 102 can be communicatively coupled to the user interface (not depicted) to convey an indication of the detected obstruction.

FIG. 3 is a time-temperature diagram 300 of a response to an airflow obstruction of a dehumidifier 100, according to an embodiment of the present disclosure. The response diagram includes a response curve 302, depicted along a temperature axis 304 and a time axis 306. The response curve 302 can depict a continual temperature of the low pressure portion 220, 222 of the fluidic circuit 106 (e.g., the evaporator 208 outlet) over time. The controller 102 can detect a plurality of data points (not depicted) corresponding to the response curve 302. For example, the controller 102 can sample data points at regular interval, such as every 100 milliseconds, one second, ten seconds, etc. The controller 102 can store one or more data points to determine a relative change over a time period. For example, the controller 102 can maintain a circular buffer of data points over time, or can store a data point of interest (e.g., a data prior or subsequent to the response curve crossing a threshold). The controller 102 can maintain an indication of time for each data point. For example, a controller 102 implementing a circular buffer of data points sampled at regular interval can store time according to a position of the data points (e.g., the controller can determine that a data point of interest, following ten additional data points taken at one second intervals, is ten seconds later than the first data point). The time may be relative or absolute (e.g., relative to another data point, or a Unix epoch timestamp).

The curve 302 includes a first portion 308, which is generally linear. The first portion 308 can include variations. For example, a pressure, density, or moisture content of air can increase or decrease a rate of evaporation of the evaporator 208. Such as change can affect a pressure or temperature detected by the sensor 104. The sensor 104 can include one or more thresholds to discriminate between expected variation of evaporator loading, and a temperature change which may be indicative of an airflow blockage. For example, the variation of the temperature may remain above a lower magnitude threshold 310, such that a potential airflow blockage can be detected based on a deviation below the lower magnitude threshold 310. In some iterations (not depicted), the controller 102 can sense a data point below the lower magnitude threshold 310, but may not detect a data point in excess of the upper magnitude threshold 312 which satisfies a further threshold (e.g., within a maximum time period). The controller 102 can determine that no airflow obstruction exists based on the failure to detect a data point in excess of the upper threshold within the maximum time period, or can detect that another condition exists, such as a filter 210 approaching an end of a service life. The controller 102 can log such information, present the information to a user (e.g., to determine a filter 210 should be changed or may be absent), or to support improvements to the controller 102 instructions.

A second portion 314 of the response curve 302 contains data points trending in a downward direction, towards a local minimum temperature 316. The second portion 314 can correspond to a drop in evaporation following a sudden drop in airflow, such as relating to an abrupt clog or blockage, failed fan, or the like. The second portion 314 can include a deviation below the lower magnitude threshold 310. The controller 102 can detect one or more data points corresponding to the low-temperature deviation. The controller 102 can store the data point to memory and continue to monitor the sensor 104. In some embodiments, the controller 102 can store a time associated with the first or last data point detected below the lower magnitude threshold 310. The time can be associated with a first time 320 (e.g., beginning) of an elapsed time. A third portion 318 of the response curve 302 includes data points trending upwards, including a deviation exceeding an upper magnitude threshold 312 at a second time 322 subsequent to the first time 320. The increase in temperature may relate to the transfer of heat from the high pressure portions of the fluidic circuit 106 (e.g., via the metering device 218, or radiated heat from the condenser 206). The controller 102 can determine an elapsed time between the first time 320 and the second time 322, and compare the elapsed time to one or more temporal threshold. For example, the various temporal thresholds may be indicative of a likelihood of various failure modes. For example, the temporal or magnitude thresholds can be indicative of a percent of airflow which is blocked (e.g., a complete blockage may lead to faster temperature rise, or more extreme magnitude deviations than a partial airflow). The controller 102 can determine, according to the comparison between thresholds and data points received from the sensor 104, various airflow blockages such as a failed fans, obstructed filters 210 or evaporators 208 (e.g., iced over, dust saturated, etc.), blocked inlet or outlet vents, etc. Each of the various blockages, which may also be referred to as obstructions or accumulations of particulate matter, may be referred to as an obstruction type. In some embodiments, the controller 102 can discriminate between obstruction types. For example, a failed fan or obstructed filter threshold can vary from a threshold associated with an obstruction of an airflow inlet vent based on positioning the dehumidifier 100 against curtains.

Although depicted as a time-temperature diagram 300, the systems and methods disclosed herein may also be employed by use of a pressure-temperature diagram, such as according to a refrigerant profile 122. For example, the controller 102 can interfaced with either of a temperature sensor 104 or pressure sensor 104 to determine the various portions of either of a time-temperature diagram 300 or a pressure-time diagram.

FIG. 4 is a time-temperature diagram 400 of a response to a defrost cycle of a dehumidifier 100, according to an embodiment of the present disclosure. The response includes an additional response curve 402, depicted along a temperature axis 304 and a time axis 306. Like other figures herein, the figure may not be provided to scale. For example, the temperature axis 304 and time axis 306 may be scaled differently than as depicted in FIG. 3. The additional response curve 402 can depict a continual temperature of the low pressure portion 220, 222 of the fluidic circuit 106 (e.g., the evaporator 208 outlet) over time. The additional response curve 402 includes a first portion 404 which may remain bound by, for example, an upper bound 410 or a lower bound 408. A second portion 406 of the additional response curve 402 indicates an increase in temperature upon an engagement of a defrost cycle (e.g., corresponding to an equalization between a low pressure portion 220, 222 and a high pressure portion 214, 216 of the dehumidifier 100).

The defrost cycle may be instantiated by analog circuitry, user input, a separate logic device from the controller 102, or so forth such that the controller 102 may not implement the defrost cycle. The controller 102 can discriminate between various profiles corresponding to various conditions of the dehumidifier. For example, the controller 102 can determine whether the profile corresponds to the defrost cycle or an obstruction incident to performing an action such as reduction of power to the compressor or conveying an indication of the condition.

The controller 102 can compare the additional response curve 402 at one or more points to the upper bound 410 or the lower bound 408 to determine if the compressor 202 is operating at a stable rate. The controller 102 can determine a slope for the second portion 406 of the additional response curve 402, determine the slope to a threshold, and determine, based on the comparison, a condition of the dehumidifier including discerning between a normal, expected operation (e.g., a defreeze cycle) and a fault or error condition (e.g., an obstruction). The controller 102 can determine a lack of a deviation between the lower bound 408. The controller can compare a time of the elevated temperature (e.g., above the upper bound 410), or additional upper bound 412. For example, the controller 102 can compare a time between a detected deviation 414, where the response curve 402 exceeds the upper bound 410 and the additional upper bound 412. Based on one or more determinations, the controller 102 can associate a profile with a condition. For example, the determinations may include those explicitly disclosed herein, or others. The condition may include those explicitly disclosed herein, or others.

FIG. 5 is a method 500 of detecting an air flow obstruction in a dehumidifier, according to an embodiment of the present disclosure. In brief summary, at operation 502, a controller 102 receives suction side temperature data from a sensor 104. At operation 504, the controller stores data points. At operation 506, the controller compares the data points to a profile. At operation 508, the controller 102 determines a condition of the device based on the comparison to the profile. At operation 510, the controller takes an action to resolve the condition.

Referring again to operation 502, the controller 102 receives temperature data from a sensor 104 for the suction side of the compressor 202. The controller 102 can receive temporally sequenced data points indicative of a temperature curve of the (refrigerant) fluidic circuit 106. For example, the temperature can be associated with an suction side of the fluidic circuit 106, such as the evaporator 208, compressor 202 inlet, or low pressure portion 220, 222 of the dehumidifier. The controller 102 can store the data points at operation 504, which can include storing an indication of a time associated with the sensor measurements. The time may be a time of the measurement, receipt, or another time associated with the data points. The time may be relative to other measurements, such as according to a sequence of data points.

Referring again to operation 506, the controller 102 compares the stored data points to a profile. The comparison can include a comparison to one or more temporal or magnitude thresholds, shape similarly, a presence of a periodic temperature curve, or another comparison. The controller 102 can determine a match with zero or more profiles based on the comparison. The profile can be indicative of one or more conditions of the dehumidifier 100. For example, a profile can be indicative of a remaining filter life, a partial or complete obstruction of airflow, a frozen evaporator, an inoperable fan, or so forth. A match can be determined based on comparing a temperature to one or more thresholds, fitting data points to a curve, or otherwise matching the data points to the profile. For example, a profile depicting a drop in temperature of the low pressure portion 220, 222 of the dehumidifier 100 followed by a subsequent rise in temperature can be matched to a profile indicating the same. The match can be discrete, or can include a confidence score, similarity score or other indicia of a confidence of a match, or a progression of a condition (e.g., an extent of a blockage or freeze-up).

Referring again to operation 508, the controller 102 can determine a condition of the dehumidifier 100 based on the comparison. For example, each profile can be associated with one or more conditions. The profile can correspond to a fault or other condition of the dehumidifier 100. The fault can include an over-pressure/over-temperature condition of a high pressure portion 214, 216 of the dehumidifier, as detected by the data received associated with the temperature sensor on the low pressure portion 220, 222 of the dehumidifier. For example, the controller 102 can determine an indication of a match to a profile, at operation 506, such that the controller 102 determines, at operation 508, that the over-pressure/over-temperature condition exists. The controller 102 can further determine a condition associated with the fault, such as a fan fault, filter blockage, or the like. In some embodiments, the controller 102 can determine the condition based on further inputs such as additional sensors or by prompting a user to check for a clogged filter or other condition. For example, the controller can match a condition to the corresponding profile, or receive an indication that a filter is not obstructed, a fan is operating, or the like (e.g., from the user interface 110).

Referring again to operation 510, the controller 102 can take an action to resolve the condition. For example, the controller 102 can reduce (e.g., remove) power from the compressor 202, provide an indication to a user (e.g., an audible or visual indication), or take another action such as another action described herein.

FIG. 6 is a method 600 of detecting an air flow obstruction in a dehumidifier 100, according to an embodiment of the present disclosure. In brief summary, at operation 602, a controller 102 can determine a lower threshold. At operation 604, the controller 102 can receive first sensor data 126. At operation 606, the controller 102 can compare a data point to the lower threshold. At operation 608, the controller 102 can store a record of the lower deviation. At operation 610, the controller 102 determine an upper threshold. At operation 612, the controller 102 can receive second sensor data 126. At operation 614, the controller 102 can compare the second sensor data 126 to the upper threshold. At 616, the controller 102 can determine whether the deviations detected at operation 606 and 614 satisfy a temporal threshold. Responsive to the satisfaction of the temporal threshold, the controller 102 can convey an indication of an obstruction at operation 618. Various operations of the present method 600 can be added, omitted, substituted, or modified. For example, the controller 102 can receive various additional data points or compare them to additional thresholds, or can interrupt an operation of a the dehumidifier, responsive to the detection of the obstruction.

Referring again to operation 602, the controller 102 can determine a lower threshold. The controller 102 can determine the lower threshold based on receiving a predefined value, such as a value received over a network or stored in a non-transitory media thereof. The threshold can be an absolute or relative threshold. For example, the controller 102 may receive a predefined value fully defining the lower threshold or may receive a value or offset (e.g., offset function) relative to a steady state operating point of the dehumidifier 100. The controller can determine a threshold offset (such as based on a standard deviation from an average operating point). The operating point can be a rolling average to follow a progression of filter life, temperature fluctuations, or so forth. In some embodiments the dehumidifier 100 can include an initial or default operating point, which may be restored upon each startup, or replaced by a most recent determined operating point. Determining the offset may include determining an operating point, such as determining an ambient temperature, or an operating temperature of the dehumidifier 100 (e.g., an evaporator 208 thereof). For example, the dehumidifier 100 can determine a temperature of the dehumidifier 100 at startup, and adjust or instantiate a magnitude threshold based thereupon. The threshold may be expressed as a temperature or temperature threshold, according to various embodiments.

Referring again to operation 604, the controller 102 can receive first sensor data 126. The sensor data 126 can be indicative of a deviation from an operating point determined at operation 602, or otherwise depart from an expected value. The first sensor data 126 can include at least one data point. The data point can include a magnitude of a temperature or pressure associated with the low pressure portion 220, 222 of a fluidic circuit 106, and can include a time of generation, receipt by the controller 102, or storage by the controller 102 such that a subsequent data point can be temporally associated therewith (e.g., to determine a temporal sequence, time interval, or the like). The controller 102 can receive sensor data 126, at regular intervals such as by polling a state of a temperature sensor 104 or a pressure sensor 104. The sensor 104 can monitor the evaporator 208 (e.g., an inlet or outlet thereof, proximal thereto, or otherwise disposed in a low pressure portion 220, 222 of the fluidic circuit 106).

Referring again to operation 606, the controller 102 can compare the data point to the lower threshold. For example, the controller 102 can compare various data points to a fixed or variable threshold to determine a deviation there-below. The controller 102 can determine a deviation time, magnitude, or other components thereof, such as by comparing a series of data points associated with the deviation. Responsive to determining the existence of the deviation, the controller 102 can proceed to operation 608.

Referring again to operation 608, the controller 102 can store a record of the lower deviation. The record can include setting a flag, selectively storing a data point, or another indication of the deviation, or can be stored according to a data storage architecture (such as a circular buffer) wherein the controller 102 can determine the deviation based on analysis of stored data. For example, the controller 102 may perform operations 606 subsequent to operation 614, which may reduce computational load (e.g., in a system with many deviations below a lower threshold 310 and few deviations above an upper threshold 312). Indeed, the controller 102 can perform various operations of the method 600 or other operations of the present disclosure in a sequence differing from the disclosed sequence.

Referring again to operation 610, the controller 102 can determine an upper threshold 312. The controller can determine the upper threshold 312 in similar fashion or with reference to the lower threshold 310. For example, the upper threshold 312 can be received or based on (e.g., offset from) an operating point of the dehumidifier 100, or the lower threshold 310. The controller 102 can receive second sensor data 126, in a similar fashion as the first sensor data 126 at operation 612, and can thereafter compare the data point to the upper threshold 312 at operation 614.

Referring again to operation 616, the controller 102 can determine whether the elapsed time between the deviations detected at operation 606 and 614 satisfy a temporal threshold. Satisfying the threshold refers to occurring within a temporal threshold, such as 3 minutes, 10 minutes, 30 minutes, etc. The elapsed time can be measured based on a beginning, minimum, center point, or completion of the first deviation or the second deviation, or other deviation attributes (e.g., the slope of the second deviation or the magnitude of the first deviation). As indicated above, some operations such as operation 616 can be performed in a different sequence than depicted. For example, the controller 102 can monitor a time elapsed after detecting the lower deviation and thereafter determine that a potential upper deviation would not satisfy the threshold (e.g., time out, by performing operation 616 in advance of operation 612). In some embodiments, the controller 102 can compare multiple thresholds, reference response curves 302, etc. to determine a presence, type, or other information regarding a potential obstruction.

Referring again to operation 618, the controller 102 can convey an indication of an obstruction. For example, the controller 102 can convey an audible or visual indication via the user interface 110, or convey a network message indicative of the dehumidifier 100 status. The controller 102 can store an indication of the obstruction, or any response received via the indication of the obstruction. For example, the controller 102 can store an indication of a silencing of an alert to verify airflow which can thereafter be accessed (e.g., to determine a failure cause). In some embodiments, the controller 102 can alter the operation of the humidifier responsive to the condition. For example, the controller 102 can reduce power to a compressor 202, such as by actuating the compressor power switch 224 to interrupt a supply of power thereto, which may reduce a pressure of the high pressure side of the dehumidifier 100, and thus avoid damage thereto.

FIG. 7 is a method 700 of detecting an air flow obstruction in a climate control system, according to an embodiment of the present disclosure. In brief summary, at operation 702, the controller 102 stores data points. At operation 704, the controller 102 detects deviations based on the stored data points. At operation 706, the controller 102 compares the deviations to a predefined threshold. At operation 708, the controller 102 determines an obstruction condition based on the comparison of the deviation.

Referring again to operation 702, the controller 102 can store data points. For example, the data points can include data points indicative of an operating point of climate control system including at least one data point indicative of a deviation. The controller 102 can store a time associated with each data point. Such a time can be an absolute or relative time. For example, the time can be stored as a human readable timestamp, epoch timestamp, offset, or other time step (e.g., according to an interrupt driven measurement, polled measurement, or number of passes through a loop of instructions of the controller 102).

Referring again to operation 704, the controller 102 can detect a plurality of deviations depicted by the data points. For example, the deviations can include the deviations corresponding to operations 606 and 616 of FIG. 6. In some embodiments the deviations may vary, for example, the deviations can be in reference to another sensor 104, such as a sensor 104 monitoring another portion of the fluidic circuit 106. For example, a mass flow sensor depicted at an inlet of the compressor.

Referring again to operation 706, the controller 102 can compare the plurality of deviations to a predefined threshold. The predefined threshold can include a threshold received by the controller 102 or a threshold determined by the controller 102 in advance of the comparison. For example, the predefined threshold can include an upper or lower magnitude threshold, or a temporal threshold relative to at least two portions of the plurality of deviations (e.g., a time elapsed between the beginning and ending of a deviation, or between two or more deviations of the plurality of deviations).

Referring again to operation 708, the controller 102 can determine an obstruction condition based on the comparison to the predefined threshold. For example, the controller 102 can determine that an obstruction exists, store the indication of the obstruction to non-volatile memory, or determine further information regarding the obstruction to convey to a user (e.g., an indication of a part to inspect, order, or replace).

FIG. 8 is a block diagram illustrating an architecture for a computer system 800 that can be employed to implement elements of the systems and methods described and illustrated herein. The computer system or computing device 800 can include or be used to implement a controller 102 or its components, and components thereof. The computing system 800 includes at least one bus 805 or other communication component for communicating information and at least one processor 810 or processing circuit coupled to the bus 805 for processing information. The computing system 800 can also include one or more processors 810 or processing circuits coupled to the bus for processing information. The computing system 800 also includes at least one main memory 815, such as a random access memory (RAM) or other dynamic storage device, coupled to the bus 805 for storing information, and instructions to be executed by the processor 810. The main memory 815 can be used for storing information during execution of instructions by the processor 810. The computing system 800 may further include at least one read only memory (ROM) 820 or other static storage device coupled to the bus 805 for storing static information and instructions for the processor 810. A storage device 825, such as a solid state device, magnetic disk or optical disk, can be coupled to the bus 805 to persistently store information and instructions (e.g., for the data repository 120).

The computing system 800 may be coupled via the bus 805 to a display 835, such as a liquid crystal display, or active matrix display. An input device 830, such as a keyboard or mouse may be coupled to the bus 805 for communicating information and commands to the processor 810. The input device 830 can include a touch screen display 835.

The processes, systems and methods described herein can be implemented by the computing system 800 in response to the processor 810 executing an arrangement of instructions contained in main memory 815. Such instructions can be read into main memory 815 from another computer-readable medium, such as the storage device 825. Execution of the arrangement of instructions contained in main memory 815 causes the computing system 800 to perform the illustrative processes described herein. One or more processors in a multi-processing arrangement may also be employed to execute the instructions contained in main memory 815. Hard-wired circuitry can be used in place of, or in combination with, software instructions together with the systems and methods described herein. Systems and methods described herein are not limited to any specific combination of hardware circuitry and software.

Although an example computing system has been described in FIG. 8, the subject matter including the operations described in this specification can be implemented in other types of digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them.

The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected,” or “operably coupled,” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interacting and/or logically interactable components.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. References to at least one of a conjunctive list of terms may be construed as an inclusive OR to indicate any of a single, more than one, and all of the described terms. For example, a reference to “at least one of ‘A’ and ‘B’” can include only ‘A’, only ‘B’, as well as both ‘A’ and ‘B’. Such references used in conjunction with “comprising” or other open terminology can include additional items.

It is important to note that the construction and arrangement of the apparatus and control system as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method operations may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present application. For example, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein.

SYSTEMS AND METHODS FOR SENSING ABNORMAL FAN OPERATION VIA COMPRESSOR SUCTION SENSOR

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