U.S. patent application number 11/442933 was filed with the patent office on 2007-12-06 for auto-balancing damper control.
This patent application is currently assigned to Ranco Incorporated of Delaware. Invention is credited to Joseph P. Rao.
Application Number | 20070277542 11/442933 |
Document ID | / |
Family ID | 38788269 |
Filed Date | 2007-12-06 |
United States Patent
Application |
20070277542 |
Kind Code |
A1 |
Rao; Joseph P. |
December 6, 2007 |
Auto-balancing damper control
Abstract
A control system for a heating, ventilating and air conditioning
system is provided. The control system regulates a temperature of a
multi-zone building using only a single thermostat or set point,
and a temperature element in each of the zones. The control system
receives inputs from the temperature elements and uses the inputs
and a control algorithm to control temperature according to the set
point and to minimize the differences between the temperature
elements in the different zones. In a two-zone building, a single
damper is used. In a building with a larger number of zones, the
number of dampers required is the same as the number of zones, less
one damper.
Inventors: |
Rao; Joseph P.; (Dublin,
OH) |
Correspondence
Address: |
REINHART BOERNER VAN DEUREN P.C.
2215 PERRYGREEN WAY
ROCKFORD
IL
61107
US
|
Assignee: |
Ranco Incorporated of
Delaware
Wilmington
DE
|
Family ID: |
38788269 |
Appl. No.: |
11/442933 |
Filed: |
May 30, 2006 |
Current U.S.
Class: |
62/186 ; 236/1B;
236/49.3 |
Current CPC
Class: |
F24F 11/76 20180101 |
Class at
Publication: |
62/186 ; 236/1.B;
236/49.3 |
International
Class: |
F24D 19/10 20060101
F24D019/10; F24F 7/00 20060101 F24F007/00; F25D 17/04 20060101
F25D017/04 |
Claims
1. A automatic balancing damper control system, comprising: a
single set point environmental controller; at least two temperature
elements, each temperature element located in a separate zone and
in communication with the environmental controller; and a control
output for a motorized damper, the damper responsive to the
controller and configured to control a flow of air to the separate
zones, wherein the controller is configured to accept temperature
inputs from the at least two temperature elements and to send the
control output for adjusting a position of the damper in accordance
with the single set point and inputs from the at least two
temperature elements.
2. The damper control system of claim 1, wherein the environmental
controller comprises a thermostat.
3. The damper control system of claim 2, wherein one of the at
least two temperature elements is integral to the thermostat.
4. The damper control system of claim 1, wherein the temperature
elements are selected from the group consisting of thermocouples
and thermistors.
5. The damper control system of claim 1, wherein the at least one
of the at least two temperature elements are in wireless
communication with the environmental controller.
6. The damper control system of claim 1, further comprising the
motorized damper.
7. The damper control system of claim 6, wherein an outlet of the
damper is split into at least two portions corresponding to the at
least two zones.
8. The damper control system of claim 1, wherein the system
comprises a plurality of temperature elements at least equal to a
number of the zones, at least one temperature element in each zone,
and further comprises a number of dampers equal to the number of
zones less one damper.
9. An automatic balancing damper control system for regulating
temperature in at least two different zones, comprising: a
thermostat positioned in one of the two zones; a temperature sensor
positioned in a different zone from the thermostat and in
communication with the thermostat; and a motorized damper
operatively connected to the thermostat, the damper positioned in
fluid communication with temperature regulating appliance at an
inlet and with each of the at least two different zones at outlets
thereof; wherein the thermostat is configured to adjust a position
of the damper in accordance with a single set point and temperature
inputs from the at least two zones.
10. The system of claim 9, wherein the thermostat comprises an
integral temperature sensor for sensing ambient temperature.
11. The system of claim 9, wherein the thermostat is configured to
bias the damper to supply more fluid flow to one of the at least
two zones when an operating mode calls for heating.
12. The system of claim 11, wherein the thermostat is configured to
bias the damper to supply more fluid flow to another of the at
least two zones when an operating mode calls for cooling.
13. The system of claim 9, wherein at least one of the temperature
elements is in wireless communication with the controller.
14. A method for automatically controlling a temperature in a
building, the method comprising the steps of: setting a single set
point for an environmental control system; measuring a temperature
of each of two zones controlled by the environmental control
system; adjustably controlling a flow of air between the two zones
by adjusting a position of a damper.
15. The method of claim 14, wherein the environmental control
system is a heating and air conditioning system.
16. The method of claim 14, wherein the step of setting the single
set point comprises setting the single set point with a
thermostat.
17. The method of claim 14, wherein the step of adjustably
controlling a flow of air between the two zones by adjusting the
position of the damper comprises the step of adjusted the flow of
air to minimize a difference between temperatures detected in the
two zones and the set point.
18. The method of claim 14, wherein the two zones comprise a
plurality of zones, the flow of air comprises a same number of
flows of air as the plurality of zones, and a number of dampers
comprises the same number of dampers as the plurality of zones,
less one.
19. The method of claim 14, wherein the step of adjustably
controlling a flow of air between the two zones by adjusting the
position of the damper comprises the step of biasing the damper to
supply more fluid flow to one of the at least two zones when an
operating mode calls for heating.
20. The system of claim 19, wherein the step of adjustably
controlling a flow of air between the two zones by adjusting the
position of the damper further comprises the step of biasing the
damper to supply more fluid flow to another of the at least two
zones when an operating mode calls for cooling.
Description
FIELD OF THE INVENTION
[0001] This invention generally relates to control systems for
heating and air conditioning, and for methods of operating heating,
ventilating, and air conditioning systems for multi-zone
control.
BACKGROUND OF THE INVENTION
[0002] Heating, ventilating, and air conditioning (HVAC) systems
provide comfort and convenience for persons using modern
residential, commercial and industrial buildings. This comfort and
convenience comes with a cost, of course, for installing and
operating the fans, furnaces, and air conditioners that make
possible such comfort and convenience. There is a great variety of
controls for operating these systems, but there may be room for
improvement in any of them.
[0003] A common occurrence in many multiple floor dwellings is that
comfort is sacrificed for cost in providing for HVAC comfort
control and efficiency. This sacrifice in efficiency usually
equates to less than desirable performance for the temperatures of
the upper and lower floors. The traditional method of improving
these symptoms is to control or balance the airflow to a favored
area. This can be done at additional cost by using automated
controlled ducting vents to achieve improved temperature
balance.
[0004] One example is U.S. Pat. No. 5,179,524, which describes a
complicated HVAC system. In this patent, a fan-powered mixing box
with a master damper supplies air from a heating or cooling unit
and sends a variable amount of air to each of a plurality of zones.
Each zone has its own thermostat and damper for controlling the
flow or air, and thus the temperature of the zone. While effective,
this is a complicated and expensive system to install. In addition,
the needs of the zones must be balanced since each has its own
controlling thermostat.
[0005] Another way to control temperature and ventilation in a
multi-zone facility is shown in U.S. Pat. No. 5,413,165. Heating
and cooling to an upper and a lower floor are adjusted by multiple
dampers and a thermostat on each level. Temperature differences
between the upper and lower levels may be evened out by directing
air from the upper level to the lower level. However, there may be
high temperature differentials between the floors.
[0006] In another example, U.S. Pat. No. 5,860,473 discloses a
climate control system with separate zones, a separate damper for
each zone, and interlocking controls. Each zone has its own
thermostat and can individually call for heating or cooling. In
this disclosure, however, if one zone is being heated, the other
zones are not allowed to call for cooling; or if one zone is being
cooled, the other zones are not allowed to call for heating. This
system provides good control for each zone, but has a very high
cost of equipment and installation. In U.S. Pat. No. 5,944,098,
each zone also has its own thermostat and sets of contacts for
calling for heating and cooling. The control system, which does not
allow simultaneous heating and cooling, requires a separate damper
for each zone. This will also be an expensive system to
operate.
[0007] What is needed is a heating, ventilating, and air
conditioning system that is simple and economical to operate, and
which is also effective to control the temperature in at least two
zones of a building.
BRIEF SUMMARY OF THE INVENTION
[0008] One embodiment is an automatic balancing damper control
system. The damper control system includes a single set point
environmental controller, at least two temperature elements, each
temperature element located in a separate zone and in communication
with the environmental controller, and a control output for a
motorized damper, the damper responsive to the controller and
configured to control a flow of air to the separate zones, wherein
the controller is configured to accept temperature inputs from the
at least two temperature elements and to send the control output
for adjusting a position of the damper in accordance with the
single set point and inputs from the at least two temperature
elements.
[0009] Another embodiment is an automatic balancing damper control
system. The damper control system includes a single set point
environmental controller, two temperature elements, each
temperature element located in a separate zone and in communication
with the environmental controller, and a control output for a
motorized damper, the damper responsive to the controller and
configured to control a flow of air to the separate zones, wherein
the controller is configured to accept temperature inputs from the
two temperature elements and to adjust a position of the damper in
accordance with the single set point and inputs from the two
temperature elements.
[0010] Another embodiment of the invention is a method for
automatically controlling a temperature in a building. The method
includes setting a single set point for an environmental control
system, measuring a temperature of each of two zones controlled by
the environmental control system, and adjustably controlling a flow
of air to the two zones by adjusting a position of a damper.
[0011] Through the various embodiments of the present invention,
value of improved energy conservation is realized. That is, by
improving airflow and waste from over heating or cooling other
zones, an energy value can be realized. Embodiments of the system
of the present invention also brings value by operating
independently as an improved air circulatory system. Further,
embodiments of the present invention provides value of when used to
balance or offset natural convection airflow currents.
[0012] Other aspects, objectives and advantages of the invention
will become more apparent from the following detailed description
when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings incorporated in and forming a part
of the specification illustrate several aspects of the present
invention and, together with the description, serve to explain the
principles of the invention. In the drawings:
[0014] FIG. 1 is a schematic view of a first embodiment;
[0015] FIG. 2 is an embodiment of a control scheme for operating a
HVAC embodiment;
[0016] FIG. 3 is a schematic view of controls for operating an HVAC
system according to the present invention;
[0017] FIG. 4 is an elevational view of a dwelling with an HVAC
embodiment; and
[0018] FIG. 5 is a schematic view of a building with multiple zones
to control.
[0019] While the invention will be described in connection with
certain preferred embodiments, there is no intent to limit it to
those embodiments. On the contrary, the intent is to cover all
alternatives, modifications and equivalents as included within the
spirit and scope of the invention as defined by the appended
claims.
DETAILED DESCRIPTION OF THE INVENTION
[0020] HVAC systems according to the present invention have a
variety of advantages over conventional systems. Not only do these
systems provide for better control of a two-zone or multi-zone
space, these systems are less expensive to install than
conventional systems. In addition, retrofits of existing systems
are also possible by merely adding a damper and a desired number of
temperature detecting elements.
[0021] A temperature detecting element, also known as a temperature
element, is typically a thermocouple or a thermistor. A
thermocouple or thermistor may be placed in each zone and wired
back to the HVAC controller. More than one thermocouple or
thermistor may also be placed in each zone for closer control of
the temperature in the zone. It is important to note that in
various embodiments of the present invention, these temperature
elements need not be thermostats, i.e., they need not be
temperature controllers. They are merely detecting elements,
detecting a nearby temperature and reporting the temperature to the
HVAC controller. If it is desired, remote temperature elements in
communication with the controller and not requiring wiring may be
used instead. These temperature elements may communicate with the
controller via an infrared link or a wireless radio-frequency (RF)
link.
[0022] FIG. 1 depicts an HVAC system embodiment according to the
present invention. HVAC system 10 includes a controller 11,
typically a microprocessor controller, and a thermostat 11a, for
setting a temperature set point for the system. The system includes
a motor 12 and a damper 13 controlled by controller 11. Adjusting
the position of the damper regulates or balances the flow of air
from an HVAC system, such as a furnace with an air conditioning
coil. The damper is preferably located at the outlet of the furnace
plenum. This improved HVAC embodiment then has two separate outlet
plenums, one to each zone. In this case, there is a lower plenum 18
for a lower floor of a dwelling or building, and an upper plenum 19
for an upper floor of the dwelling or building. The upper and lower
floors each have a temperature sampling device 14, 15, such as a
thermocouple, that is in communication with the controller 11.
[0023] The controller receives signals from the temperature
sampling devices and uses these signals, a temperature set point,
and a control algorithm stored in the controller or in a memory
attached to the controller, to automatically turn on heating or
cooling from the HVAC system and to adjust the position of the
damper. A variety of control algorithms may be used in deciding the
position of the damper, and how the damper control is integrated
with the furnace/air conditioning controls. For example, the
purpose of having a two-zone control is to equalize the
temperatures in the zones. That is, the control algorithm may
attempt to equalize the temperatures in the zones within a certain
range, e.g., .+-.two degrees F. In one embodiment, if the
temperature elements within the two zones are within two degrees of
each other, say 70.degree. F. and 72.degree. F., the controller
will make no adjustments to the damper.
[0024] In this embodiment, the algorithm may be designed so that if
the temperature difference is three degrees or more, and the HVAC
fan is running, the damper position will adjust a certain amount to
route more air to the level requiring additional heating or
cooling. The algorithm should be integrated with the control system
for the furnace/air conditioner, which will decide whether
additional cooling or heating for both zones is required upon
reaching a certain differential from the set point. Any desired
algorithm, such as a proportional, integral and derivative (PID)
algorithm, may be used to control the damper position and thus to
adjust the relative temperatures of the zones.
[0025] A diagram outlining this HVAC control scheme is depicted in
FIG. 2. Control scheme 20 begins with a step 21 of sampling the
temperatures of an upper and a lower floor of a building.
Alternatively, the two zones may be on the same level of a
building, such as a home, an office, or a retail store. The
temperature information is sent to a HVAC controller with a control
algorithm. The controller calculates the difference between the set
point temperature and the temperatures indicated in the zones. The
controller then calculates whether the zones require 22 heating or
cooling. The control scheme then looks at the differential between
the upper and lower temperatures to see whether the damper should
be adjusted to favor (i.e., send more air to) the lower level 24 or
the upper level 25. If necessary, the controller directs a damper
adjustment. For example, if the season requires heating and the
lower level is cooler than the upper level, the damper position
will move to allow more heated air to flow to the lower level. If
the season requires cooling and the lower level is cooler than the
upper level, the damper position will move to allow more cooled air
to flow to the upper level. After this iteration, the control
scheme will then return 25 to the main program 21 and the sampling
and control cycle begins again.
[0026] Embodiments are not limited to the ones already described.
For example, if the zones are large, or if one zone is large, more
than one temperature element may be located in a zone. FIG. 3
depicts an embodiment in which each zone has two temperature
elements. Environmental control system 30 includes a control
housing 31 with a microprocessor controller 32 which may include a
memory. This system includes a single thermostat 34 for controlling
a temperature. Each zone may have two or more temperature elements,
preferably located separately in the zone. In this zone, the first
floor F1 has two temperature elements 35, 36 and the second floor
F2 also has two temperature elements 37, 38. The controller
receives signals from the temperature elements and uses this
information, the set point of thermostat 34, and a control
algorithm to determine and adjust a position of damper 37.
[0027] The control algorithm may use the temperatures and the
temperature differences in each zone in any desired manner. For
instance, the algorithm may average the two temperatures on each
floor or zone and make damper adjustments based on the averages.
Control over the system temperature may be kept tighter if the
algorithm uses the extremes of the temperature differences to
adjust damper position. In such an embodiment, there is only one
thermostat controlling the temperature set point. The temperature
elements in this embodiment are not thermostats and do not
independently control a temperature. The control system accepts
inputs from a plurality of temperature elements and uses these
inputs to calculate whether heating or cooling is required, and
also to calculate a desired position of the damper. The control
system then activates heating, cooling, or an adjustment of the
damper position.
[0028] A preferred embodiment of an HVAC system is disclosed in
FIG. 4. HVAC system 40 is installed in a two-zone building 41 that
includes a first floor or zone 42a and a second floor or zone 42b.
Each zone has an HVAC air inlet plenum 47a, 47b, a cold air return
48a, 48b, and a temperature element 49a, 49b. The temperature
elements are in communication with system controller 43, which is
also in communication with a thermostat 43a which determines a
temperature set point for the building. The HVAC system includes a
furnace 45 with an air conditioning coil which is used to heat and
cool building 41. Furnace with air conditioning coil 45 receives
the cold air returns 48a, 48b and blows heated and cooled air
outputs through outlet plenum 46a, which is located directly atop
furnace 45 and is split into zone inlet plenums 47a, 47b. Motorized
damper 46b is located directly atop plenum 46a for economy of
installation.
[0029] Embodiments are not limited to two zones. The advantages of
the present discovery may be embodied in systems with more than two
zones. An example with three zones is depicted schematically in
FIG. 5. An HVAC system 50 for controlling more than two zones
includes a controller 51, preferably a microprocessor controller
which may include a memory for storing at least an algorithm for
operating the system. The system is controlled by a single
thermostat 51a by which controller 51 receives a set point for
heating or cooling. The heating and cooling, as well as
ventilation, are provided by furnace 52 which includes heating
elements and an air conditioning coil. A fan 53 moves air that is
heated or cooled or ventilates the building using system 50.
[0030] Furnace plenum 56 is preferably mounted atop furnace 52.
First damper 57, mounted atop plenum 56, splits the flow of air
between first floor or zone 54a and second and third floors or
zones 54b, 54c. Second damper 58 is mounted downstream and further
splits the air stream between second and third floors 54b, 54c. The
positions of the dampers are controlled by controller 51 using
temperature signals received from temperature elements 55a, 55b,
55c located in each of the floors or zones. The position of damper
58 is controlled primarily by the difference between the
temperatures of elements 54b, 54c. The position of damper 57 is
controlled primarily by the difference between the temperature of
element 55a and the remaining temperature elements.
[0031] System 50 uses only a single HVAC temperature setting to
control multiple zones. System 50 controls the temperature of the
multiple zones, automatically balancing the temperatures of the
zones, by using at least one temperature element in each zone, and
a number of dampers that is equal to the number of zones, less one
damper. As noted above, more than one temperature element may be
used if the individual zones are large, or if only one zone is
large and a closer degree of control over the damper(s) that
control the flow of air to that zone.
[0032] All references, including publications, patent applications,
and patents cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically set forth in its entirety herein.
[0033] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) is to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to practicing the
invention.
[0034] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *