Embodiments of the invention relate generally to temperature control systems and methods.
Fan coil units are often used to control indoor air temperatures. Generally, a fan coil unit includes a water or direct expansion coil, a fan, and ductwork to distribute the air. In some instances, significant energy costs are incurred by fan coil units due to inadequate controls. Additionally, without proper control, air temperatures may not be able to be maintained effectively.
In one embodiment, a method of controlling a temperature of one or more zones using a fan includes inputting a temperature set point for the one or more zones and inputting a temperature control band for the one or more zones. The temperature control band represents an acceptable temperature variation of the one or more zones. The method also includes initializing the fan to operate at a first speed setting, determining a relationship between the temperature of the one or more zones, the temperature set point, and the temperature control band, and modulating a speed of the fan between the first speed setting and a second speed setting based at least partially on the determined relationship. The first speed setting is less than the second speed setting. The fan speed is set to the second speed setting as the temperature of the one or more zones exceeds a sum of the temperature set point and at least a portion of the temperature control band. The fan speed is set to the first speed setting as the temperature of the one or more zones approaches the temperature set point.
In another embodiment, a fan control system configured to control a fan and an air temperature control mechanism for controlling a temperature of one or more zones, includes an input module, a fan speed control module, and an air temperature control module. The input module receives a signal from a temperature sensor which generates a signal indicative of the temperature of the one or more zones; receives a signal from a temperature selection device which allows a user to select a temperature set point for the one or more zones; and stores a control band parameter representing an acceptable temperature variation of the one or more zones. The fan speed control module modulates the fan speed between a first speed setting and a second speed setting, the second speed setting being greater than the first speed setting. The fan speed control module initially operates the fan to the first speed setting, switches the fan speed to the second speed setting upon the temperature of the one or more zones exceeding the sum of the temperature set point and the control band parameter, and switches back to the first speed setting upon the temperature of the one or more zones returning to the sum of the temperature set point and the control band parameter. The air temperature control module modulates the temperature of the air temperature control mechanism to maintain the temperature of the one or more zones at approximately the temperature set point.
In another embodiment, a method of programming a temperature control system controller for controlling the temperature of one or more zones includes programming a first temperature control loop and a second temperature control loop. The first control loop initially operates a fan at a first speed setting, increases the fan speed to a second speed setting upon the temperature of the zone exceeding a sum of a temperature set point and at least a portion of a temperature control band, and decreases the fan speed to the first speed setting upon the temperature of the one or more zones returning to the temperature set point. The second temperature control loop maintains the temperature of the one or more zones at the temperature set point by decreasing the temperature of the air temperature control mechanism upon the temperature of the one or more zones exceeding a sum of the temperature set point and at least a portion of the control band, and increasing the temperature of the air temperature control mechanism upon the temperature of the one or more zones returning to the temperature set point.
Embodiments herein can be implemented in new control systems or retrofitted into existing systems. Further, embodiments can be useful in a host of temperature-controlled environments, such as, for example, industrial production facilities, medical buildings, manufacturing assemblies, laboratories, and ships.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
As should also be apparent to one of ordinary skill in the art, the systems shown in the figures are models of what actual systems might be like. Many of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application-specific integrated circuits (“ASICs”). Terms like “controller” may include or refer to both hardware and/or software. Furthermore, throughout the specification, capitalized terms are used. Such terms are used to conform to common practices and to help correlate the description with the coding examples, equations, and/or drawings. However, no specific meaning is implied or should be inferred simply due to the use of capitalization. Thus, the claims should not be limited to the specific examples or terminology or to any specific hardware or software implementation or combination of software or hardware.
The multi-speed fan 105 of the FCU 100 supplies airflow to the one or more zones that the FCU services. In one embodiment, this is accomplished using a series of fan blades, as known in the art. As such, the size, operating speed, and capacity of the fan 105 may vary according to the application. In some embodiments, the coil 110 is a water or direct expansion coil that is used to cool the airflow passing over the coil 110. In other embodiments, the coil 110 can be used to heat the air passing over the coil 110. The valve 115 controls the amount of water or other liquid that is supplied to the coil 110. Accordingly, the valve 115 can effectively control the temperature of the coil 110. For example, in one embodiment, if the valve 115 is in a completely closed position, little or no liquid is supplied to the coil 110, and the coil 110 is allowed to attain room temperature. Alternatively, if the valve 115 is in a fully open position, a maximum amount of liquid is supplied to the coil 110, and maximum cooling is attained. The valve 115 transmits and receives signals from the controller 125, as described in greater detail below. The temperature sensor 120 measures the temperature of the zone to which the FCU 100 is supplying airflow. In some embodiments, the temperature sensor 120 is a stand-alone thermometer that transmits a signal indicative of the zone temperature to the controller 125. In other embodiments, the temperature sensor 120 is integrated into or coupled to the controller 125, for example, forming a single control and sensing unit (e.g., a thermostat device).
Generally, the controller 125 can be a variety of suitable electronic devices, such as, for example, one or more integrated circuits (“ICs”), a microcomputer, a programmable logic controller (“PLC”), and/or other computing device. As such, the controller 125 may include both hardware and software components, and is meant to broadly encompass the combination of such components. In the embodiment shown in
Generally, the input module 200 receives signals from components of the FCU 100, which signals can then be used by the other modules. In some embodiments, the input module 200 also stores certain parameters that are used by the other modules. For example, in one embodiment, the input module 200 receives, from the temperature sensor 120, a signal indicative of the temperature of the zone to which the FCU 100 is supplying airflow. The input module 200 also receives a signal from a temperature selection device (e.g., a thermostat), which allows a user to select a temperature set point, or desired temperature, of the zone. Additionally, a user can store a control band parameter in the input module 200 that represents an acceptable temperature variation of the one or more zones. In other embodiments, the input module 200 also receives a signal from the fan 105 that is indicative of fan speed, and a signal from the valve 115 that is indicative of valve position.
The fan speed control module 205 controls the speed at which the fan 105 operates. In some embodiments, the fan speed control module 205 stores a set of rules or processes (e.g., the processes described with respect to
The temperature control module 210 modulates the temperature of the coil 110. More specifically, the temperature control module 210 modulates the temperature of the coil 110 by modulating the position of the valve 115. In some embodiments, cold and hot controls may be separated, such that the cooling control module 215 is used to control the flow of cold liquid through the coil 110, and the heating control module 220 is used to control the flow of hot liquid through the coil 110. In other embodiments, the cooling control module 215 and the heating control module 220 are not separated. Similar to the fan speed control module 205, in some embodiments, the temperature control module 210 stores one or more sets of rules or processes (e.g., the processes described with respect to
After providing the necessary inputs, the next step in the process 300 is to check if a fan command is on (step 310). As described above, the fan start/stop command can be input by a user with an input device such as a thermostat. In another embodiment, the fan start/stop command may be automatically controlled by the controller 125. For example, if the temperature of the zone that is being conditioned falls below a predetermined temperature, the fan command can be automatically initialized. If the fan command is not on, the fan 105 is turned off (step 315). If the fan command is on, the fan 105 is initialized to run at the slow speed setting (step 320). After the fan 105 has been initialized and is running at the slow setting, the mode (e.g., heating mode or cooling mode) is determined (step 325). In one embodiment, the heating or cooling mode is selected automatically by the controller 125 according to the temperature of the zone. For example, if the zone temperature is above the zone temperature set point, the controller 125 automatically selects the cooling mode. Similarly, if the zone temperature is below the zone temperature set point, the controller 125 automatically selects the heating mode. In other embodiments, a user may be able to manually select the heating or cooling mode using an input device. If the controller 125 is not in the cooling mode, the process 300 returns to step 320, and the fan 105 continues to run at slow speed. If the controller 125 is in the cooling mode, the next step in the process 300 is to check whether the zone temperature is greater than or equal to the combination or sum of the zone temperature set point and a control band. In some embodiments, the zone temperature set point is approximately 72 to 74 degrees Fahrenheit and the control band is approximately ±1 degree Fahrenheit. In other embodiments, however, the zone temperature set point and control band may be set to other values. For example, in one embodiment, a user can select the zone temperature set point using a thermostat device.
If the zone temperature is less than the sum of the temperature set point and the control band, the process 300 returns to step 320, and the fan 105 continues to run at the slow speed setting. If, however, the zone temperature is greater than or equal to the sum of the temperature set point and the control band, the fan speed is increased to a higher speed setting (step 335). The higher speed setting supplies the zone that the FCU 105 is conditioning with a greater amount of cooled air, thereby increasing the speed at which the zone is cooled. After switching to the higher speed setting, the process continues by checking whether the zone temperature is less than or equal to the zone temperature set point (step 340). If the zone temperature has not reached the zone temperature set point, the process 300 returns to step 335, and the fan 105 continues to operate at the higher speed setting. Upon the zone temperature reaching the zone temperature set point, the process 300 returns to step 310, and the fan 105 returns to operating at a slower speed setting. The process 300 continues to be evaluated until the fan command is turned off.
Returning to step 435, if the temperature of the zone is greater than or equal to the sum of the zone temperature set point and one quarter of the control band (step 430), but less than or equal to the sum of the zone temperature set point and three quarters of the control band (step 435), the fan speed is increased to the middle speed setting (step 450), and remains at the medium speed setting until the zone temperature is less than or equal to the zone temperature set point (step 455). Upon the temperature falling to the zone temperature set point, the process 400 returns to step 410, and the speed of the fan is reduced to the slowest speed setting. The process 400 continues to be evaluated until the fan command is turned off.
If the cooling mode is activated (step 515), the controller 125 checks if the zone temperature is greater than or equal to the zone temperature set point less the control band (step 525). If the zone temperature is less than the zone temperature set point less the control band, the valve 115 is fully closed (step 515). If, however, the zone temperature is greater than or equal to the zone temperature set point less the control band, the controller 125 checks if the zone temperature is greater than the zone temperature set point (step 530). If the zone temperature is less than or equal to the zone temperature set point, the position of the valve is modulated to maintain the zone temperature set point within the zone (step 535). This position modulation can be accomplished using a variety of methods including, for example, a proportional integral (“PI”) control loop. If the zone temperature is greater than the zone temperature set point, the valve 115 is opened completely (step 540) to attain the greatest potential cooling.
If the heating mode is activated (step 520), the controller 125 checks if the zone temperature is less than the zone temperature set point less the control band (step 545). Additionally, if the heating mode is activated, the coil 110 may be operated such that air passing over the coil 110 is heated. For example, upon activation of the heating mode, hot liquid, such as water, can be passed through the coil 110 so that the coil 110 substantially heats the air. In another embodiment, the FCU 100 can include two separate coils, with one coil being activated with the cooling mode and the other coil being activated with the heating mode. If the zone temperature is greater than or equal to the zone temperature set point less the control band, the valve 115 is closed completely (step 515). If, however, the zone temperature is less than the zone temperature set point less the control band, the valve 115 is modulated to maintain the zone temperature set point (step 550). As described with respect to the cooling mode above, the valve 115 can be modulated according to a PI control loop or other suitable control scheme. The process 500 continues by checking if the zone temperature is greater than the zone temperature set point (step 555). If the zone temperature is less than or equal to the zone temperature set point, the process 500 returns to step 550, and the valve 115 continues to be modulated to maintain the zone temperature set point. If the zone temperature is greater than the zone temperature set point, the valve is closed (step 515). Upon completion, the process 500 can be repeated as needed to control the temperature of the zone.
In some embodiments, each of the processes illustrated in
Various features and advantages of the invention are set forth in the following claims.
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/727,812, filed on Oct. 18, 2005, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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60727812 | Oct 2005 | US |