U.S. patent application number 15/006651 was filed with the patent office on 2016-07-28 for remote monitoring of an hvac system for fault detection and diagnostics.
This patent application is currently assigned to Trane International Inc.. The applicant listed for this patent is Trane International Inc.. Invention is credited to Gang (Jacky) Chen, William David Daugherty, III, Carl L. Garrett, Mark E. Groskreutz, Mahfuz Imam, Karl J. Mutchnik, Jeffrey L. Stewart.
Application Number | 20160217674 15/006651 |
Document ID | / |
Family ID | 56432424 |
Filed Date | 2016-07-28 |
United States Patent
Application |
20160217674 |
Kind Code |
A1 |
Stewart; Jeffrey L. ; et
al. |
July 28, 2016 |
REMOTE MONITORING OF AN HVAC SYSTEM FOR FAULT DETECTION AND
DIAGNOSTICS
Abstract
A method and system for detecting and diagnosing faults in a
heating, ventilation and air conditioning (HVAC) system includes a
remote server receiving data from sensors associated with the HVAC
system. The data received includes measured sensor data, from both
HVAC equipment and co-located sensors, and identifying criteria for
identifying the piece of equipment associated with the sensor
and/or identifying a location of the sensor, which may or may not
be on or in the HVAC equipment. A probability that a fault exists
and/or a likelihood of occurrence of a fault in one of the pieces
of the equipment is calculated based on the data received, and an
alert is generated in accordance with an analysis thereof, which
may include comparison of the probability and/or likelihood with
predetermined threshold(s).
Inventors: |
Stewart; Jeffrey L.;
(Whitehouse, TX) ; Mutchnik; Karl J.; (Tyler,
TX) ; Groskreutz; Mark E.; (Tyler, TX) ; Imam;
Mahfuz; (Tyler, TX) ; Daugherty, III; William
David; (Gladewater, TX) ; Chen; Gang (Jacky);
(Tyler, TX) ; Garrett; Carl L.; (Tyler,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Trane International Inc. |
Davidson |
NC |
US |
|
|
Assignee: |
Trane International Inc.
Davidson
NC
|
Family ID: |
56432424 |
Appl. No.: |
15/006651 |
Filed: |
January 26, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62107603 |
Jan 26, 2015 |
|
|
|
62107595 |
Jan 26, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 11/30 20180101;
F24F 2110/00 20180101; G08B 21/187 20130101; G05B 23/0227 20130101;
F24F 11/58 20180101; F24F 11/62 20180101; F24F 11/63 20180101; G05B
15/02 20130101 |
International
Class: |
G08B 21/18 20060101
G08B021/18; F24F 11/00 20060101 F24F011/00 |
Claims
1. A method for detecting and diagnosing faults in a heating,
ventilation and air conditioning system, the method comprising:
receiving, by a server, data from a plurality of sensors associated
with a heating, ventilation and air conditioning system, the data
including measured data from each of the plurality of sensors and
identifying criteria associated therewith, the identifying criteria
including a location of the sensor associated with the measured
data, at least one of the plurality of sensors being associated
with a piece of equipment in the heating, ventilation and air
conditioning system, the identifying criteria for the at least one
sensor further identifying the piece of equipment associated
therewith; detecting, by the server, a fault in the piece of
equipment based on the data received; and generating an alert, by
the server, of the fault in response to the detecting.
2. The method of claim 1, further comprising: calculating a
probability of the fault in the piece of equipment based on the
data received; and generating the alert in response to the
probability of the fault exceeding a predetermined threshold.
3. The method of claim 1, further comprising transmitting the alert
to one of a user device and a thermostat in the heating,
ventilation and air conditioning system, the alert being viewable
on a display associated with the thermostat.
4. The method of claim 1, further comprising storing the alert in a
database associated with the server for access by a user.
5. The method of claim 1, wherein receiving data includes receiving
event data generated in response to an event, the measured data
comprising a record of the event and a date and time of occurrence
of the event.
6. The method of claim 5, wherein receiving data further includes
continuously receiving the measured data at predetermined
intervals, the data further comprising a date and time of receiving
the measured data, the method further including aggregating the
event data and the measured data received at the predetermined
intervals, and calculating a probability of the fault based on the
aggregated data, wherein detecting the fault is based on the
calculated probability.
7. The method of claim 1, wherein receiving data, by the server,
further includes collecting the data associated with one of a
common type of equipment and a common mode of equipment from a
plurality of heating, ventilation and air conditioning systems.
8. The method of claim 7, further comprising analyzing the
collected data associated with the one of the common type and the
common mode of equipment to determine a set of rules for
calculating a probability of a particular fault occurring in the
equipment associated with the one of the common type and the common
mode.
9. The method of claim 6, further comprising storing the aggregated
data, the probability calculated, and a record of the alert
generated, in a database operably connected to the server.
10. The method of claim 1, further comprising diagnosing one or
more causes of the fault based on the data received, and
communicating the alert as a fault notification including the fault
and the one or more causes to one of a user device and a thermostat
display.
11. The method of claim 10, further comprising importing diagnostic
data from a third-party device operably connected to the server and
analyzing the data using the diagnostic data to diagnose the one or
more causes of the fault.
12. The method of claim 1, the method further comprising acquiring
the measured data by one of a dedicated electronic gathering device
operably connected to the heating, ventilation and air conditioning
system, a thermostat in the heating, ventilation, and air
conditioning system, and a control unit in the heating,
ventilation, and air conditioning system, the server receiving the
measured data from the one of the dedicated electronic gathering
device, the thermostat, and the control unit in response to a query
from the server.
13. The method of claim 1, wherein the fault is a most likely
existing fault, the detecting, by the server, further comprising:
detecting a plurality of possible faults in the piece of equipment
based on the data received; and ranking the plurality of possible
faults in ranked order of most to least likely existing fault in
the piece of equipment based on the data received, wherein the
alert generated further includes the plurality of possible faults
and the ranked order.
14. A system for detecting and diagnosing faults in a heating,
ventilation and air conditioning system, the system comprising: a
server, the server being communicatively coupled to a heating,
ventilation and air conditioning system; wherein the server is
configured to: receive data from a plurality of sensors associated
with a heating, ventilation and air conditioning system, the data
including measured data from each of the plurality of sensors and
identifying criteria associated therewith, the identifying criteria
including a location of the sensor associated with the measured
data, at least one of the plurality of sensors being associated
with a piece of equipment in the heating, ventilation and air
conditioning system, the identifying criteria for the at least one
sensor further identifying the piece of equipment associated
therewith; detect a fault in the piece of equipment based on the
data received; and generate an alert in response to the fault being
detected.
15. The system of claim 14, wherein the server is further
configured to: calculate a probability of the fault in the piece of
equipment based on the data received; and generate an alert in
response to the probability of the fault exceeding a predetermined
threshold.
16. The system of claim 15, wherein the data includes event data
comprising a record of an event and a date and time of occurrence
of the event, and measured data continuously received at
predetermined intervals, the system further comprising a database
operably connected to the server, wherein the server is further
configured to: continuously receive the measured data at
predetermined intervals; aggregate the event data and the
continuously received measured data; calculate the probability of
the fault based on the aggregated data; and store the aggregated
data, the probability calculated, and a record of the alert
generated, in the database.
17. The system of claim 14, wherein the server is further
configured to: collect data associated with one of a common type
and a common mode of equipment from a plurality of heating,
ventilation and air conditioning systems; and analyze the collected
data associated with the one of the common type and the common mode
of equipment to determine a set of rules for calculating a
probability of a particular fault occurring in the equipment
associated with the one of the common type and the common mode.
18. The system of claim 14, the server further configured to:
diagnose one or more causes of the fault based on the data
received; and communicate the alert in a fault notification
including the fault and the one or more causes of the fault to one
of a user device and a thermostat display.
19. The system of claim 15, wherein the server is operably
connected to one of a dedicated electronic gathering device, a
thermostat, and a control unit in the heating, ventilation, and air
conditioning system, wherein the one of the dedicated electronic
gathering device, the thermostat, and the control unit acquires the
data associated with the equipment, the server further configured
to query the one of the dedicated electronic gathering device, the
thermostat, and the control unit to forward the data.
20. A computer-readable device to store instructions that, when
executed by a processing device, cause the processing device to
perform operations comprising: receiving data from a plurality of
sensors associated with a heating, ventilation and air conditioning
system, the data including measured data from each of the plurality
of sensors and identifying criteria associated therewith, the
identifying criteria including a location of the sensor associated
with the measured data, at least one of the plurality of sensors
being associated with a piece of equipment in the heating,
ventilation and air conditioning system, the identifying criteria
for the at least one sensor further identifying the piece of
equipment associated therewith; calculating a probability of a
fault in the piece of equipment based on the data received; and
generating an alert in response to the calculated probability
exceeding a predetermined threshold.
21. The computer-readable device of claim 20, the operations
further comprising diagnosing one or more causes of the fault based
on the data received, and communicating the alert as a fault
notification including the fault and the one or more causes of the
fault to one of a user device and a thermostat display.
22. A method for detecting and diagnosing faults in a heating,
ventilation and air conditioning system, the method comprising:
receiving, by a server, data from a plurality of sensors associated
with a heating, ventilation and air conditioning system, the data
including measured data from each of the plurality of sensors and
identifying criteria associated therewith, the identifying criteria
including a location of the sensor associated with the measured
data, at least one of the plurality of sensors being associated
with a piece of equipment in the heating, ventilation and air
conditioning system, the identifying criteria for the at least one
sensor further identifying the piece of equipment associated
therewith; calculating, by the server, a likelihood of occurrence
of a fault in the piece of equipment based on the data received;
generating an alert, by the server, of the fault in response to the
likelihood of occurrence exceeding a predetermined threshold; and
transmitting the alert to one of a user device and a thermostat in
the heating, ventilation and air conditioning system, the alert
being viewable on a display associated with the thermostat.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Application Ser. No. 62/107,603 entitled "REMOTE
MONITORING OF AN HVAC SYSTEM FOR FAULT DETECTION AND DIAGNOSTICS"
and filed Jan. 26, 2015, and U.S. Provisional Application Ser. No.
62/107,595 entitled "DIAGNOSTIC DATA BUS FOR ACQUIRING AND
COMMUNICATING DIAGNOSTIC INFORMATION FROM HVAC SYSTEMS" and filed
Jan. 26, 2015, the entirety of each of which is hereby incorporated
by reference herein for all purposes.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates generally to heating,
ventilation and air conditioning (HVAC) systems. More specifically,
this disclosure relates to remotely monitoring an HVAC system to
detect and diagnose faults.
[0004] 2. Background
[0005] Current methods and systems for detecting and diagnosing
faults that occur in heating, ventilation and air conditioning
(HVAC) systems typically require local diagnostic tools and manual
processes. For example, a homeowner may notice a fault or alert
code produced locally by the HVAC system, prompting the homeowner
to place a telephone call to the equipment dealer. A service
technician is then sent by the dealer to the home to diagnose the
problem locally, typically by applying troubleshooting skills and,
in some cases, by accessing built-in diagnostic tools installed in
the various pieces of equipment comprising the HVAC system.
[0006] Many problems are associated with such local diagnostics.
For instance, sensors and transducers (referred to collectively
herein as sensors) are not typically installed in all of the
required places within present systems to allow detection of a wide
range of faults that may be of interest. Moreover, even if
additional diagnostic capabilities were included at the equipment
level (adding additional expense to the system), there is no
ability within the separate pieces of HVAC equipment to analyze
data from a system level for assisting in fault detection and
diagnosis (FDD). As a result, degradation of the operation or
performance of HVAC equipment can go unmonitored and undetected for
a long period of time, potentially resulting in expensive equipment
damage and decreased system efficiency.
[0007] Accordingly, there is a need for a system that monitors,
detects and diagnoses faults in HVAC systems.
[0008] SUMMARY
[0009] The present disclosure is directed to a method and system
for remotely monitoring HVAC systems for fault detection and
diagnosis. Advantageously, embodiments of the method and system can
provide the diagnostic capability to detect degradation in
performance or operation before major equipment damage occurs. As a
result, additional benefits provided by the method and system of
the present disclosure may include lowering the energy consumption
and increasing the product life of current HVAC systems and
equipment.
[0010] In one aspect, the present disclosure is directed to a
method for detecting and diagnosing faults in a heating,
ventilation and air conditioning system. The remote server receives
data from a plurality of sensors associated with the heating,
ventilation and air conditioning system. The sensor data includes
measured data from each of the plurality of sensors and identifying
criteria associated therewith. The identifying criteria include a
location of the sensor associated with the measured data. At least
one of the plurality of sensors is associated with a piece of
equipment in the heating, ventilation and air conditioning system.
The identifying criteria for the at least one sensor further
identifies the particular piece of equipment associated therewith.
The method includes detecting a fault in the piece of equipment
based on the data received from the plurality of sensors. An alert
is then generated in response to the fault being detected.
[0011] In embodiments, the method includes calculating a
probability of the fault existing in any one of the pieces of
equipment in the HVAC system based on the data received. In
embodiments, the alert is generated in response to the probability
of the fault exceeding a predetermined threshold.
[0012] In embodiments, a likelihood of an occurrence of a
particular fault is additionally or alternatively calculated based
on the data received.
[0013] In various embodiments, analysis is performed to compare the
calculated probability of existence of the fault (and/or likelihood
of occurrence of the fault) to various criteria based on the data
to determine if an alert should be generated. In embodiments, the
criteria may include predetermined thresholds, and the alert may be
generated in response to one or more conditions, which may include
the probability of the fault (and/or likelihood of occurrence)
exceeding the predetermined threshold.
[0014] In embodiments, the method includes transmitting the alert
to a user device or to a thermostat in the heating, ventilation and
air conditioning system. In the latter case, the alert is then
viewable on a display associated with the thermostat.
[0015] The alerts may alternatively, or additionally, be stored in
a database associated with the server for access by a user.
[0016] In some embodiments, the data received by the server
includes event data generated in response to an event. The event
data, in embodiments, is received at the time the event occurs. The
measured data corresponding to the event includes a record of the
event that identifies the event and a date and time of occurrence
of the event.
[0017] In additional embodiments, the server also continuously
receives measured data at predetermined intervals, including a date
and time of receiving the measured data. The method further
includes aggregating the event data and the continuously received
data, and calculating the probability of the fault based on the
aggregated data. The aggregated data, the probability calculated,
and a record of the alert generated, may be stored, in embodiments,
in a database operably connected to the server.
[0018] The methods of the present disclosure can be applied to
monitor a plurality of heat, ventilation and air conditioning
systems to determine whether any of the equipment within any of
those systems requires service and/or maintenance.
[0019] In embodiments, the server also collects sensor data
associated with a common type of the equipment or a common mode of
equipment from a plurality of heating, ventilation and air
conditioning systems. The collected data associated with the common
type or common mode of the equipment can then be analyzed to
determine a set of rules for calculating a probability of an
existing fault and/or a likelihood of an occurrence of a particular
fault occurring in the equipment.
[0020] The server, in embodiments, also receives data from logic
embedded in at least one of the pieces of the equipment.
[0021] Embodiments also include diagnosing one or more causes of
the fault, once detected, based on the data received, and
communicating the alert as a fault notification including the fault
and the one or more causes of the fault to a user device and/or to
a thermostat display. Diagnostic data for analyzing the cause(s) of
the fault may be provided by a third- party, such as a dealer or
manufacturer, and importing the diagnostic data via a third-party
device (e.g., server) operably connected to the server. The sensor
data received by the server is then analyzed using the diagnostic
data to diagnose cause(s) of the fault.
[0022] In various embodiments, the method includes first acquiring
the measured data at the site of the heating, ventilation and air
conditioning (HVAC) system using any one or more of a dedicated
electronic gathering device operably connected to the HVAC system,
a thermostat in the HVAC system, and a control unit in the HVAC
system. The acquired data may then be forwarded to the server for
processing. Alternatively, before or in addition to forwarding the
acquired data, at least for one of the pieces of equipment in the
HVAC system, the probability of faults can be calculated and
cause(s) of the fault diagnosed by the dedicated electronic
gathering device, thermostat and/or the control unit at the site of
the HVAC system based on the acquired data.
[0023] Embodiments may include forwarding the acquired data to the
server in response to the server querying the dedicated electronic
gathering device, the thermostat and/or the control unit to
transmit the acquired data.
[0024] In embodiments, the fault that is detected is a most likely
existing fault. The method further includes detecting a plurality
of possible faults in the piece of equipment based on the data
received; and ranking the plurality of possible faults in order of
most to least likely existing fault in the piece of the equipment
based on the data received, wherein the alert generated further
includes a list of the plurality of possible faults and their
ranked order.
[0025] In another aspect, the present disclosure is directed to a
system for detecting and diagnosing faults in a heating,
ventilation and air conditioning system includes a server, which is
communicatively coupled to the heating, ventilation and air
conditioning system. The server is configured to receive data from
a plurality of sensors associated with equipment in the HVAC
system. The data received includes measured data from each of the
plurality of sensors and identifying criteria associated therewith.
The identifying criteria includes a location of the sensor
associated with the measured data. At least one of the plurality of
sensors is associated with a piece of equipment in the heating,
ventilation and air conditioning system. The identifying criteria
for the at least one sensor further identifies the particular piece
of equipment associated therewith. The server is further configured
to detect a fault in the piece of equipment based on the data
received, and to generate an alert in response to the fault being
detected.
[0026] In embodiments, the server is further configured to
calculate a probability of the fault in the piece of equipment
based on the data received. The alert may be generated in response
to the probability of the fault exceeding a predetermined
threshold.
[0027] In embodiments, the data received includes event data
comprising a record of an event and a date and time of occurrence
of the event, and measured data continuously received at
predetermined intervals. The system can also include a database
operably connected to the server. The server is further configured
to continuously receive the measured data at predetermined
intervals and aggregate the event data and the continuously
received measured data. The server is also configured to calculate
the probability of the fault based on the aggregated data, and
store the aggregated data, the probability calculated, and a record
of the alert generated, in the database.
[0028] The system of the present disclosure can be configured to
monitor a plurality of heat, ventilation and air conditioning
systems to determine whether any of the equipment within any of
those systems requires service and/or maintenance.
[0029] In some embodiments, the server is further configured to
collect data associated with a common type or common mode of
equipment from a plurality of heating, ventilation and air
conditioning systems. The server then analyzes the collected data
associated with the common type or common mode of equipment to
determine a set of rules for calculating the probability of a
particular fault occurring in the equipment associated with the
common type or common mode.
[0030] In embodiments, the server is further configured to diagnose
one or more causes of the fault based on the data received, and
communicate the alert in a fault notification including the fault
and the one or more causes of the fault to one of a user device and
a thermostat display.
[0031] The server, in various embodiments, is operably connected to
one of a dedicated electronic gathering device, a thermostat, and a
control unit in the heating, ventilation, and air conditioning
system, any one or more of which acquires the data associated with
the equipment. The server may be further configured to query any
one of the dedicated electronic gathering device, the thermostat
and the control unit to transmit the acquired data.
[0032] In yet another aspect, the present disclosure is directed to
a computer-readable device to store instructions that, when
executed by a processing device, cause the processing device to
perform operations. The operations include receiving data from a
plurality of sensors associated with a heating, ventilation and air
conditioning system. The data received includes measured data from
each of the plurality of sensors and identifying criteria
associated therewith.
[0033] The identifying criteria includes a location of the sensor
associated with the measured data. At least one of the plurality of
sensors is associated with a piece of equipment in the heating,
ventilation and air conditioning system. The identifying criteria
for the at least one sensor further identifies the particular piece
of equipment associated therewith. The operations further include
calculating a probability of a fault in the pieces of the equipment
based on the data received, and generating an alert in response to
the probability of the fault exceeding a predetermined
threshold.
[0034] In embodiments of the computer-readable device, the
operations further include diagnosing one or more causes of the
fault based on the data received, and communicating the alert as a
fault notification including the fault and the cause(s) of the
fault to one of a user device and a thermostat display. In
additional embodiments, the operations further include analyzing
the data using diagnostic data imported from a third-party device
to diagnose causes of the fault.
[0035] Other features and advantages will become apparent from the
following description of the preferred embodiments, taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Various embodiments of the disclosed system and method are
described herein with reference to the accompanying drawings, which
form a part of this disclosure.
[0037] FIG. 1 is a schematic diagram of an embodiment of a system
of the present disclosure communicatively coupled to a heating,
ventilation and air conditioning system;
[0038] FIG. 2A is a block diagram representation of an embodiment
of a method in accordance with the present disclosure
[0039] FIG. 2B is a block diagram representation of another
embodiment of a method in accordance with the present
disclosure;
[0040] FIG. 2C is a block diagram representation of still another
embodiment of a method in accordance with the present
disclosure;
[0041] FIG. 2D is a block diagram representation of yet another
embodiment of a method in accordance with the present
disclosure;
[0042] FIG. 2E is a block diagram representation of yet still
another embodiment of a method in accordance with the present
disclosure;
[0043] FIG. 3 is a system flow diagram representation of some
embodiments of the present disclosure; and
[0044] FIG. 4 is a schematic diagram of another embodiment of a
system of the present disclosure communicatively coupled to a
heating, ventilation and air conditioning system.
[0045] The various aspects of the present disclosure mentioned
above are described in further detail with reference to the
aforementioned figures and the following detailed description of
exemplary embodiments.
DETAILED DESCRIPTION
[0046] The present disclosure is directed to a method and system
for remotely monitoring and analyzing data associated with
equipment in a heating, ventilation and air conditioning (HVAC)
system for fault detection and diagnosis (FDD). Embodiments of the
method and system provide the diagnostic capability to detect the
existence of faults and/or to predict a likelihood of a fault by
collecting data from sensors and equipment and forwarding the data
to a remote server for fault detection and diagnosis. Accordingly,
system-wide operational data from the HVAC system is applied to
detect and diagnose faults, and to predict faults, in any of the
equipment in the system. In addition, the server can monitor a
plurality of HVAC systems for detecting and diagnosing faults in
any one of the pieces of equipment in the plurality of HVAC
systems. Particular embodiments described herein include
calculating probabilities that a fault exists and/or likelihoods of
a future occurrence of a fault in a piece of equipment, based on
the data collected from the HVAC system. In embodiments, the
probabilities, and/or likelihoods of a future occurrence, are
analyzed and compared to certain criteria to determine when alerts
should be generated. For example, the probabilities and/or
likelihoods of occurrence are compared to predetermined thresholds
for generating alerts of the existence and/or likelihood of
occurrence of the fault.
[0047] Particular illustrative embodiments of the present
disclosure are described hereinbelow with reference to the
accompanying drawings; however, the disclosed embodiments are
merely examples of the disclosure, which may be embodied in various
forms. Well-known functions or constructions and repetitive matter
are not described in detail to avoid obscuring the present
disclosure in unnecessary or redundant detail. Therefore, specific
structural and functional details disclosed herein are not to be
interpreted as limiting, but merely as a basis for the claims and
as a representative basis for teaching one skilled in the art to
variously employ the present disclosure in virtually any
appropriately detailed structure. In this description, as well as
in the drawings, like-referenced numbers represent elements which
may perform the same, similar, or equivalent functions. The word
"exemplary" is used herein to mean "serving as an example,
instance, or illustration." Any embodiment described herein as
"exemplary" is not necessarily to be construed as preferred or
advantageous over other embodiments. The word "example" may be used
interchangeably with the term "exemplary."
[0048] Embodiments of methods of the present disclosure are
described herein in terms of functional block components which may
correspond to one or more various processing steps. It should be
appreciated that such functional blocks may be realized by any
number of hardware and/or software components configured to perform
the specified functions. For example, the present disclosure may
employ various integrated circuit components, e.g., memory
elements, processing elements, logic elements, look-up tables, and
the like, which may carry out a variety of functions under the
control of one or more microprocessors or other control
devices.
[0049] Referring to an embodiment of a system 10 of the present
disclosure as shown in FIG. 1, for example, in various embodiments,
the hardware and/or software components for implementing one or
more of the functional blocks or method steps may be implemented on
one or more server(s) 12 or distributed between any combination of
one or more server(s) 12, a user device 14, 15 operably connected
to a heating, ventilation and air conditioning (HVAC) system 16, a
thermostat 18 in the HVAC system 16, and a control unit 20 in the
HVAC system 16.
[0050] Similarly, the software elements of the present disclosure
may be implemented with any programming or scripting language such
as C, C++, C#, Java, COBOL, assembler, PERL, Python, PHP, or the
like, with the various algorithms being implemented with any
combination of data structures, objects, processes, routines or
other programming elements. The object code created may be executed
by any suitable processing device, on a variety of operating
systems, including without limitation Apple OSX.RTM., Apple
iOS.RTM., Google Android.RTM., HP WebOS.RTM., Linux, UNIX.RTM.,
Microsoft Windows.RTM., and/or Microsoft Windows Mobile.RTM..
[0051] It should be appreciated that the particular implementations
described herein are illustrative of the disclosure and its best
mode and are not intended to otherwise limit the scope of the
present disclosure in any way. Examples are presented herein which
may include sample data items which are intended as examples and
are not to be construed as limiting. Indeed, for the sake of
brevity, conventional data networking, application development and
other functional aspects of the systems (and components of the
individual operating components of the systems) are not described
in detail herein. It should be noted that many alternative or
additional functional relationships or physical or virtual
connections may be present in a practical electronic system or
apparatus.
[0052] As will be appreciated by one of ordinary skill in the art,
the present disclosure may be embodied as a method, a device, e.g.,
a server device, configured to implement the methods disclosed
herein, and/or a computer program product. Accordingly, the present
disclosure may take the form of an entirely software embodiment, an
entirely hardware embodiment, or an embodiment combining aspects of
both software and hardware. Furthermore, the present disclosure may
take the form of a computer program product on a computer-readable
storage medium having computer-readable program code means embodied
in the storage medium. Any suitable computer-readable storage
medium may be utilized, including hard disks, CD-ROM, DVD-ROM,
optical storage devices, magnetic storage devices, semiconductor
storage devices (e.g., flash memory, USB thumb drives) and/or the
like.
[0053] Computer program instructions embodying the present
disclosure may also be stored in a computer-readable memory that
can direct a computer or other programmable data processing
apparatus to function in a particular manner, such that the
instructions stored in the computer-readable memory produce an
article of manufacture, including instruction means, that implement
the function specified in the description or flowchart block(s).
The computer program instructions may also be loaded onto a
computer or other programmable data processing apparatus to cause a
series of operational steps to be performed on the computer or
other programmable apparatus to produce a computer-implemented
process such that the instructions that execute on the computer or
other programmable apparatus provide steps for implementing the
functions specified in the present disclosure.
[0054] Referring again to FIG. 1, for example, in one embodiment,
the server 12 includes at least a processing device or devices 22,
memory including computer readable memory or storage 24 for storage
of software, instructions, or executable code, which when executed
by the processing device(s) 22 causes the processing device(s) 22
to perform methods or method steps of the present disclosure, which
may be embodied at least in part in programming instructions 26
stored on or retrievable by the server 12. It will be appreciated
by those of ordinary skill in the art that such components 22, 24
and programming instructions 26 for performing the methods or
method steps of the present disclosure may be also be distributed
among various devices, which may include user devices 14, 15 such
as computers, laptops, mobile devices, phones, tablets, and so on,
and programmable logic installed in the thermostat 18 and/or other
control units 20, if present, in the HVAC system.
[0055] It should be appreciated by those of ordinary skill in the
art that the disclosed methods may also be embodied, at least in
part, in application software that may be downloaded, in whole or
in part, from either a public or private website or an application
store ("app store") to a user device such as a mobile device
including a phone, tablet and so on. In another embodiment, the
disclosed system and method may be included in the mobile device
firmware, hardware, and/or software. In another embodiment, the
disclosed systems and/or methods may be embodied, at least in part,
in application software executing within a webserver to provide a
web-based interface to the described functionality.
[0056] In yet other embodiments, all or part of the disclosed
systems and/or methods may be provided as one or more callable
modules, an application programming interface (e.g., an API), a
source library, an object library, a plug-in or snap-in, a dynamic
link library (e.g., DLL), or any software architecture capable of
providing the functionality disclosed herein.
[0057] The term "sensors" as used herein refers collectively to
both sensors and transducers as commonly used in the art, and
includes sensors associated with a particular piece of equipment
and/or control unit in the HVAC system, such as a temperature
sensor in a thermostat. Sensors may be located on or operably
connected to certain HVAC equipment. Other sensors co-located with
an HVAC system may, or may not be operably connected to HVAC
equipment, but may still be used in accordance with methods of the
present disclosure to analyze the data collected for detecting a
probability of a fault in the HVAC equipment. Examples of sensors
from which data may be collected for analysis in accordance with
the present disclosure include, but are not limited to,
temperature, humidity, pressure, occupancy, smoke, light, motion,
security sensors, and so on. Data that may be acquired from sensors
and/or equipment (which may include sensors or embedded
controllers) includes, but is not limited to, measured data
readings (e.g., temperature, pressure, humidity, and so on), set
point (e.g., a user-defined temperature setting), current state
(e.g., an "occupied" or "unoccupied" reading from an occupancy
sensor), and modes of operation (e.g., heat or cool mode of a
thermostat).
[0058] The term "identifying criteria" as used herein refers to any
data or identifier used to identify a particular piece of equipment
or sensor, for example, without limitation, its location, or a
category or type of the piece of equipment or sensor, and may
include a type, model, serial number, manufacturer, dealer, and so
on.
[0059] The term "user" is collectively used to refer to any user of
the system of the present disclosure, which can include a
manager/operator (for example, a home owner, or a building
manager/operator) of an HVAC system, a dealer or manufacturer of
certain HVAC equipment being monitored, and others. Different
categories of users may have different types of access to the data
generated by the methods and system of the present disclosure. A
suitable user device includes a computer or mobile device,
including a smart phone, tablet, personal digital assistant and so
on, that can be configured for a particular user. In embodiments, a
user device configured for a manager/homeowner can also be used to
monitor and control the HVAC system.
[0060] A "fault" as used herein refers to a departure from an
acceptable range of one or more operating parameters. A
"probability" is used herein generically to refer to a relative
probability, although it is contemplated that the scope of the
present disclosure can also include absolute probabilities.
[0061] Referring now to FIG. 1, an embodiment of a system 10 of the
present disclosure for detecting and diagnosing faults in a
heating, ventilation and air conditioning (HVAC) system 16 is
shown. The system 10 includes a server 12 communicably coupled to
the HVAC system 16 and specially configured to implement and
execute the methods of the present disclosure. The server 12 may
also be configured to establish communications between user devices
14 and the HVAC system 16, via the Internet 27, for controlling a
thermostat and, optionally, other units that may be included in a
home automation system via their user devices 14. Accordingly, the
server 12 may be configured to send various alerts in accordance
with the present disclosure to the same user devices 14 used for
home automation. In additional embodiments, the server 12 can send
other types of information to other user devices 15 configured for
appropriate access by dealers and/or manufacturers of equipment in
the HVAC system 16.
[0062] Referring still to the embodiment of FIG. 1, the HVAC system
16 includes a thermostat 18 and may include various additional
control units 20, each of which may be operable via a touch-screen
panel as well as via user devices 14 operated by a homeowner, for
example, of the system 16. Additional equipment in the HVAC system
16 may include, but is not limited to, furnaces and heating
equipment, air conditioners, filters, air purifiers, ventilation
equipment, chillers, pumps, and air handlers.
[0063] The equipment may include both indoor equipment 40 and
outdoor equipment 42, each of which may include sensors 32 operably
connected to and/or embedded in the equipment. Some equipment may
include embedded logic controllers 34 for monitoring and
controlling operation. Thermostat 18 and/or control unit 20
communicates with indoor 40, outdoor equipment 42, and other HVAC
equipment via control bus 41. Control bus 41 may use any
communications protocol suitable for use with HVAC equipment 40,
42. For example, and without limitation, where indoor equipment 41
and/or outdoor equipment 42 employ single- or dual-speed motors,
control bus 41 may include a number of switched circuits which
operates in accordance with standard HVAC color-coding schemes (RC,
RH, C, Y, W, Y2, W2, etc.). Where indoor equipment 41 and/or
outdoor equipment 42 employ variable-speed motors, control bus 41
may include a digital signaling interface such as, without
limitation, CANbus, RS-485, ComfortLink II.TM., ClimateTalk.TM.,
and the like. In embodiments, control bus 41 operates using both
24v switched circuits and digital signaling protocols to flexibly
accommodate any combination of HVAC equipment.
[0064] Additional sensors 36 may be co-located with the system 16
and may or may not be operably connected to equipment within the
HVAC system 16. Such sensors 36 may include, but are not limited
to, occupancy, smoke, light, motion, security, humidity, pressure
sensors, and so on. As described further herein, in various
embodiments of methods of the present disclosure, data from these
sensors 36 is collected, stored, and analyzed along with data from
equipment in the HVAC system 16, including data from sensors 32 and
logic controllers 34, to assess current operational parameters and
trends in the equipment and HVAC system 16. The data is then
analyzed to detect and diagnose faults. The probability that a
fault exists in any one or more of the pieces of the equipment may
be calculated based on the sensor data. In addition, a likelihood
of occurrence of a fault in the future, if a particular condition
is not corrected within a certain period of time, for example, may
be calculated based on the data.
[0065] As will be described further below, various types of data
are generated by the sensors associated with the HVAC system 16.
Referring still to FIG. 1, embodiments of the HVAC system 16 in
accordance with the present disclosure include an electronic
gathering device 44 configured to acquire data from any components
associated with the system 16, including the control unit(s) 20,
thermostat 18, both indoor 40 and outdoor equipment 42, and other
sensors 36, and forward the data via the Internet 27, for example,
to the server 12 for processing. Though the embodiments of the
methods and system are described herein in the context of fault
detection and diagnosis of equipment in a single HVAC system, the
scope of the present disclosure includes applying the methods and
system of the present disclosure to monitoring a plurality of heat,
ventilation and air conditioning systems to predict, detect, and
diagnose faults within any of the equipment within any of those
systems in accordance with the present disclosure.
[0066] Though only one HVAC system is shown in FIG. 1, in
embodiments of the present disclosure, data may be collected by the
server 12 for processing from a plurality of HVAC systems.
Advantageously, by collecting data from a plurality of HVAC
systems, more accurate models can be developed for predicting
faults in different types of equipment from sensor data within an
HVAC system.
[0067] The electronic data gathering device 44 may be a dedicated
electronic gathering device provided in or near the HVAC system 16
for gathering and transmitting data to the server 12. For example,
the electronic data gathering device 44 may be located in, on, or
in proximity to an indoor air handling or indoor furnace unit
acquiring indoor and/or outdoor type HVAC system data.
[0068] The device 44 may be part of the system 16 upon installation
or, in some embodiments, configured for integration with an
existing HVAC system. In various embodiments, the electronic
gathering device 44 may be any one of a data acquisition and
measurement device, a printed circuit board assembly, a control
unit, a system, and so on that is configured to acquire the data
from the various components in and near the HVAC system 16 and
communicate the acquired data to the remote server 12. In some
embodiments, the electronic data gathering device is also
configured to receive serial data from embedded logic controllers
34 within the HVAC equipment and forward the serial data to the
server 12.
[0069] The electronic gathering device 44 is operably connected to
the server 12 for transmission of the acquired data thereto and
configured for transmitting the data by any suitable connection,
either wired or wireless 46, of any appropriate type, including but
not limited to WiFi, cellular, Ethernet, POTS via modem, and so
on.
[0070] In some embodiments, the thermostat 18 of the HVAC system is
operably connected to the data gathering device 44, has Internet
connectivity 48, e.g., WiFi, Ethernet, and so on, and can provide
the data pathway from the electronic data gathering device 44 to
the central remote server 22 via the Internet 27. Using the
thermostat in this way spares the expense of adding an additional
piece of hardware to the system 16 to serve this purpose and
removes the requirement for the electronic data gathering device 44
to have WiFi, Ethernet, cellular, or land line range and
connectivity to the server 12. The thermostat can acquire data both
internally to the thermostat and via sensors, e.g. temperature,
humidity, etc., and will forward that data to the remote server 12
along with additional data acquired by the data gathering device
44.
[0071] In some embodiments, the thermostat 18 is configured to
provide the functionality of the electronic data gathering device
44 by collecting additional data from equipment and co-located
sensors, e.g., as well as from other control units if present, and
sending the data along with the internal thermostat data, either
directly or indirectly, to the remote server 12 for processing.
[0072] In additional embodiments, the thermostat 18 can forward
data to the remote server 12 that is generated both internally to
the thermostat and from sensors, e.g. temperature, humidity, etc.,
and, if present, additional control unit(s) 20 can also
independently, in parallel, forward data to the remote server
12.
[0073] In some embodiments, the communication between the
electronic data gathering device 44 and the server 12 is
bidirectional. In other embodiments, the communication is
unidirectional from the electronic data gathering device 44 to the
remote server 12.
[0074] Referring still to FIG. 1, in some embodiments, the data
gathering device 44 may acquire data via serial communication from
the electronic controls 34 embedded in various pieces of equipment
within the HVAC system 16, as well as via wired or wireless
sensors. In additional embodiments, instead of using a single data
gathering device 44, a first (indoor) data gathering device 50 can
be located at, on, or in an indoor air handling or furnace unit 40,
for example, which acquires primarily indoor type HVAC system data,
and a second (outdoor) data gathering device 52 can be located at,
on, or in an outdoor unit 42 of the HVAC system, which acquires
primarily outdoor type HVAC system data. Indoor data gathering
device 50 and outdoor data gathering device 52 communicate via
diagnostic data bus 51. In some embodiments, diagnostic data bus 51
includes a wired link using a serial communications protocol (e.g.,
CANbus or RS-485), while in some embodiments, diagnostic data bus
51 includes a wireless link (e.g., WiFi). In various embodiments,
data may be acquired from one or both of the first (indoor) data
gathering device 50 and the second (outdoor) data gathering device
52 and forwarded from one or both, respectively, to the remote
server 12.
[0075] In addition to the embodiments disclosed herein, any other
suitable device known in the art may be used to acquire the data
for forwarding to the server 12 in accordance with the present
disclosure. Referring still to FIG. 1, the data that is received by
the server 12 may be stored in a database 54 operably connected to
the server 12.
[0076] Referring now to FIG. 4, an embodiment of a system 250 in
accordance with the present disclosure includes a dealer diagnostic
portal 251, an end-user diagnostic portal 252, a thermostat
UI-based diagnostic portal 253, and a local diagnostic portal 254.
The diagnostic portals 251-254 display information received from
server 12, enable a user to input data into information server 12,
and facilitate user interaction with server 12. Diagnostic portals
251-254 are configured to provide access to data according to the
requirements of the intended user. For example, dealer diagnostic
portal 251 and local diagnostic portal 254 are initially configured
to display low-level diagnostic data which would be of interest to
service technician. Examples of such technician-level data include
compressor inlet/outlet temperature and pressure, compressor input
current, evaporator inlet/outlet temperature, and indoor unit
pressure. End-user diagnostic portal 252 and thermostat UI-based
diagnostic portal 253 are initially configured to display a higher
level of diagnostic detail better suited for an end-user, such as
remaining filter life, refrigerant charge, and time remaining in
the current service interval. In some embodiments, any of
diagnostic portals 251-254 are user-configurable to display a
higher level, or a lower level, of diagnostic data than that for
which it was originally configured. For example, a user may wish to
configure a thermostat UI-based diagnostic portal 253 to include
lower level (technician-level) data, which could be used assist a
technician working on-site to conduct his or her diagnosis.
[0077] Diagnostic portals 251-254 include an alert function whereby
detected faults or other reminders communicated from server 12 are
displayed in real-time to quickly inform the dealer and/or the end
user of the existence of a system problem or a maintenance
reminder. In some embodiments, any one or all of diagnostic portals
251-254 include the capability to relay a secondary fault alarm to
a second or backup user device, such as a text message, email
message, voice announcement via telephone, and so forth. Because
service personnel and end-users of HVAC equipment are both promptly
informed, as appropriate, when faults within their HVAC system(s)
occur, improved dealer operating efficiency, reduced response time,
greater end-user comfort and satisfaction, and lower HVAC lifecycle
costs may be realized.
[0078] In embodiments, web-based dealer portal 251 and a web-based
end-user portal 252 is embodied as a web page and/or within
application software (e.g., a mobile or desktop application). In
embodiments, thermostat UI-based diagnostic portal 253 includes one
or more user interface elements of a thermostat, for example,
graphical user interface elements presented on a touchscreen
display, pre-defined elements of an LCD panel, hardware input
devices (buttons, switches, rotary controls), and/or seven segment
or multi-segment displays. Local diagnostic portal 254 typically
includes hardware input devices, seven segment displays, and the
like, although other user interface elements are contemplated
within the scope of the present disclosure. In some embodiments,
local diagnostic portal 254 is integrated with a controller module
included with indoor equipment 40 and/or outdoor equipment 42. In
some embodiments, local diagnostic portal 254 is included with
indoor diagnostic module 50 and/or outdoor diagnostic module
52.
[0079] FIG. 2A illustrates an embodiment of a method of the present
disclosure to detect and diagnose faults in a heating, ventilation
and air conditioning system that is operably connected to a server
12 as described above. In accordance with an embodiment of the
method 60, the server receives, at 62, data from sensors associated
with the heating, ventilation and air conditioning system. At 66,
the data is analyzed to determine whether an alert should be
generated and transmitted to that indicates a fault exists based on
the data. In embodiments, an alert may also, or alternatively, be
generated to indicate a likelihood of occurrence of a fault in any
of the pieces of equipment based on the data.
[0080] Referring still to FIG. 2A, in embodiments, at 64, a
probability that a fault exists and/or a likelihood of a fault
occurring in one or more of the pieces of the equipment is
calculated based on the data received. A comparison and analysis of
the calculated probability of the fault (and/or the likelihood of
the fault) to various criteria associated with the HVAC system and
equipment parameters is then performed at 66. An alert is
generated, if warranted, based on the analysis.
[0081] FIG. 2B illustrates an embodiment of a method of the present
disclosure to detect and diagnose faults in a heating, ventilation
and air conditioning system that is operably connected to a server
12 as described above. In accordance with the method 70, the server
receives, at 72, data from sensors associated with the heating,
ventilation and air conditioning system. At 76, a probability of a
fault in one or more of the pieces of the equipment is calculated
based on the data received. An alert is then generated at 78 in
response to the calculated probability of the fault exceeding a
predetermined threshold.
[0082] In various embodiments in accordance with the present
disclosure, a prioritized list of possible faults and/or causes may
be generated based on the data received.
[0083] The data received by the server includes measured data from
each of the sensors and identifying criteria associated with the
sensor. For example, if the sensor is embedded in (including as
embedded logic), on, or is operatively connected to a piece of
equipment in the HVAC system 16, the identifying criteria
preferably identifies the piece of the equipment. Such identifying
criteria may include a type, model, serial number, manufacturer,
dealer, and so on associated with the equipment, and may also
include a location of the equipment/sensor (a room, space, floor,
building, or outside location, for example, where the
equipment/sensor is located, and/or a geographic location). In some
embodiments, data is also received from sensors co- located with,
but not operably connected to any equipment. The identifying
criteria may include a type of the sensor as well as location
information (a room, space, floor, building, or outside location,
for example, where the sensor is located, and/or a geographic
location).
[0084] Because data from a number of sensors may be acquired by the
remote server from different types of equipment and from different
locations within the HVAC system, a system view of the performance
or operation of the HVAC system at any particular time and under
current known conditions is obtained in accordance with the present
disclosure. This system-wide view enhances the capability of the
system and methods of the present disclosure to accurately predict
an equipment fault and alert the user to the impending fault, even
before it occurs. Probabilities of the existence of a fault and/or
likelihoods of occurrence of a fault of a piece of equipment can be
determined based on an analysis of various parameters determined
from the data collected.
[0085] In one implementation of an embodiment of the methods of the
present disclosure, for example, the data received from a
thermostat indicates that a call for cooling and indoor equipment
airflow is present. Additional data collected from the HVAC system
indicates that no cooling is detected. Based on the data, it is
determined that a fault exists in the cooling mode, and a lack of
proper operation of the compressor is diagnosed as the likely
cause. An appropriate alert and fault notification indicating a
need for compressor service can then be generated and transmitted
to the appropriate users.
[0086] Referring to FIG. 2C, in another embodiment 80, historical
data is received by the server at 82 from sensors and equipment
across a plurality of HVAC systems. By aggregating and analyzing
the historical data associated with each type of equipment, and/or
with a particular mode of equipment in the plurality of HVAC
systems over a period of time, algorithms, or a set of rules, for
calculating the probability of faults, and/or likelihood of
occurrence of faults, associated with various types of equipment
can be determined at 84 from the historical data, as well as
threshold values for generating alerts. The rules can then be
stored at 86 for use in calculating the probability that a
particular fault exists, and/or a likelihood that the particular
fault could occur in a particular of equipment.
[0087] In embodiments, predetermined threshold values may indicate
a likelihood of occurrence of a fault in a piece of equipment if no
corrective action is taken. Accordingly, the methods of the present
disclosure provide a means for alerting a user to a problem even
before a fault actually occurs, thereby avoiding expensive damage.
In embodiments, fault threshold values are predetermined, such that
probabilities above the predetermined fault threshold value
indicate that a fault likely exists, i.e., that the equipment is
already operating outside acceptable operational ranges.
[0088] Referring to FIG. 2D, in accordance with another embodiment
of a method 100 of the present disclosure, the server receives, at
102, data from sensors associated with the heating, ventilation and
air conditioning system. The server receives certain data
continuously 103 at predetermined intervals and other data,
referred to as event data, upon occurrence of an event 105, such
as, but not limited to, a change of state, operation, or condition
(such as a power transition or cycling of the HVAC equipment), an
alert, or a user-specified event. In some embodiments, a time stamp
(date and time of day the data was generated) may be associated and
collected with the continuous data and/or the record of the event.
In accordance with other embodiments, the time-stamp may be added
at the time the data is received. The continuously received data
and event-generated data is then aggregated at 104 and a
probability of an equipment fault is calculated at 106 based on the
aggregated data.
[0089] An alert, or fault notification, is then generated at 108 in
response to the calculated probability of the fault exceeding a
predetermined threshold and may be automatically transmitted at the
time the alert occurs to a user device and/or to a thermostat
display. At 110, the alerts may be stored along with, optionally,
the sensor data and probabilities of a fault associated with each
piece of equipment.
[0090] In some embodiments, certain alerts may be accessible only
to dealers and/or manufacturers, only to field service personnel,
or only to the home owner or building manager, depending on the
type of fault, for example. Some alerts may be accessible to any
type of user. Access to the alerts may be provided, for example,
based on user permissions, via a web-based service portal accessed
via a computer or other suitable device. Such alerts may also be
communicated to a suitable user device by text messages, emails,
digital voice phone call or voice message, via a website log in to
a web-based service, a web app, a smartphone app, and/or any other
methods known in the art, when and as they occur.
[0091] In some embodiments, the transmission of alerts, or fault
notifications, from the server to field service personnel or
owners/operators of the HVAC systems can be manually triggered
instead of automatically-generated, or can be a combination of
both. For example, the content of an automatically-generated fault
notification may be tailored for the appropriate field service
personnel. Such field service notifications may then be manually
forwarded to the owner/operator of the HVAC system by the field
service personnel at his or her discretion, optionally after
manually altering the notification, if appropriate. In some
embodiments, the server can also be queried at any time by
authorized users, e.g., by field personnel, the HVAC system
manufacturer, or dealer, for the analysis to begin on a specific
HVAC system, and/or for obtaining HVAC system data, and/or for the
real-time and/or historical data analysis results for any one or
multiple HVAC systems as appropriate and as needed.
[0092] Additional embodiments of a method 150 are shown in FIG. 2E.
At step 160, the measured data from the sensors is acquired by one
of a dedicated electronic gathering device operably connected to
the heating, ventilation and air conditioning system, a thermostat
in the heating, ventilation, and air conditioning system, and a
control unit in the heating, ventilation, and air conditioning
system. In one embodiment, the acquired data is then forwarded at
162 to the server 12, optionally, in response to a query from the
server.
[0093] At 164, a fault is indicated, for example, by a probability
exceeding, or reaching, a predetermined threshold, and at 168
causes of the fault are diagnosed based on the acquired data. The
detection and diagnosis in preferred embodiments are performed by
the server after forwarding the data thereto. In other embodiments,
the detection and diagnosis of certain faults may be performed by
the dedicated electronic gathering device, the thermostat, or the
control unit. In some embodiments, algorithms and information for
performing the diagnostics are imported from a third-party server
or database, or any type of computer, smart device, and so on
associated with a dealer or manufacturer of the equipment.
[0094] An alert is then generated at 170 in response to detecting
the fault and transmitted to a user device and/or to a thermostat
display. At 172, the alerts of detected faults may be stored along
with the diagnoses.
[0095] FIG. 3 provides a system flow diagram representation of
various embodiments of methods of the present disclosure,
summarizing a flow of data between sensors in the HVAC system 16,
the server 12, and dealer 15 and homeowner devices 14 in accordance
with embodiments of the present disclosure. In the embodiment
shown, the sensor data 200 associated with the HVAC system 16 are
received and analyzed by the server 12. In some embodiments, as
shown, the analytic algorithms 202 for fault detection and
diagnosis in accordance with the present disclosure are resident on
the server 12 and can be easily upgraded with new analytics 204 as
needed.
[0096] Once a fault is detected, it may be transmitted to a
thermostat display 206 as well as to appropriate users via the
Internet 27. For example, a dealer portal 208 is provided to a
web-based service hosted on the server 12. Dealers can access
certain data stored in the database 54 through the portal 208,
which is related to the operation of the HVAC equipment monitored
by the dealers, including information related to the fault
detections and diagnoses generated in accordance with the present
disclosure and stored in the database 54. Records of the events and
also, preferably, historical logs of continuously generated sensor
data are also stored in the database 54 and may be accessed by the
dealers. Analytics of the historical sensor and event data may also
be made available to the dealers through the portal 208. Sensor
data 200 may be received by the server 12 via a thermostat in the
HVAC system, as described herein, and/or via one or more dedicated
electronic gathering device(s) 50, 52. Dealers may also enter data
via the portal 208, such as diagnostic information, or baseline
information on equipment which may be used by the server 12 to
determine thresholds, for example, for indicating a fault.
[0097] It should be understood by those of ordinary skill in the
art that while embodiments disclosed herein may refer to a
homeowner operating an HVAC system associated with a single home,
the system and methods of the present disclosure are not limited
thereto and can be integrated with HVAC systems that allow
management of a number of spaces or buildings in accordance with
methods known to those of ordinary skill in the art.
ASPECTS
[0098] It is noted that any of aspects 1-13 below can be combined
with each other in any combination and combined with any of aspects
14-19, or with any of aspects 20-21 or with aspect 22. Any of
aspects 14-19, 20-21 and 22 can be combined with each other in any
combination.
[0099] Aspect 1. A method for detecting and diagnosing faults in a
heating, ventilation and air conditioning system, the method
comprising: receiving, by a server, data from a plurality of
sensors associated with a heating, ventilation and air conditioning
system, the data including measured data from each of the plurality
of sensors and identifying criteria associated therewith, the
identifying criteria including a location of the sensor associated
with the measured data, at least one of the plurality of sensors
being associated with a piece of equipment in the heating,
ventilation and air conditioning system, the identifying criteria
for the at least one sensor further identifying the piece of
equipment associated therewith; detecting, by the server, a fault
in the piece of equipment based on the data received; and
generating an alert of the fault in response to the detecting.
[0100] Aspect 2. The method according to Aspect 1, further
comprising calculating a probability of the fault in the piece of
equipment based on the data received; and generating the alert in
response to the probability of the fault exceeding a predetermined
threshold.
[0101] Aspect 3. The method according to Aspect 1-2, further
comprising transmitting the alert to one of a user device and a
thermostat in the heating, ventilation and air conditioning system,
the alert being viewable on a display associated with the
thermostat.
[0102] Aspect 4. The method according to any of Aspects 1-3,
further comprising storing the alert in a database associated with
the server for access by a user.
[0103] Aspect 5. The method according to any of Aspects 1-4,
wherein receiving data includes receiving event data generated in
response to an event, the measured data comprising a record of the
event and a date and time of occurrence of the event.
[0104] Aspect 6. The method according to any of Aspects 1-5,
wherein receiving data further includes continuously receiving the
measured data at predetermined intervals, the data further
comprising a date and time of receiving the measured data, the
method further including aggregating event data generated in
response to an event and the measured data received at the
predetermined intervals, and calculating a probability of the fault
based on the aggregated data, wherein the fault is detected based
on the calculated probability.
[0105] Aspect 7. The method according to any of Aspects 1-6,
wherein receiving data, by the server, further includes collecting
the data associated with one of a common type of the equipment and
a common mode of the equipment from a plurality of heating,
ventilation and air conditioning systems.
[0106] Aspect 8. The method according to any of Aspects 1-7,
further comprising collecting data associated with one of a common
type of the equipment and a common mode of the equipment of the
equipment from a plurality of heating, ventilation and air
conditioning systems, and analyzing the collected data associated
with the common type or common mode of the equipment to determine a
set of rules for calculating the probability of a particular fault
occurring in the equipment associated with the common type or
common mode.
[0107] Aspect 9. The method according to any of Aspects 1-8,
further comprising storing the data received, a probability of the
fault calculated based on the data, and a record of the alert
generated, in a database operably connected to the server.
[0108] Aspect 10. The method according to any of Aspects 1-9,
further comprising diagnosing causes of the fault based on the data
received, and communicating the alert as a fault notification to
one of a user device and a thermostat display.
[0109] Aspect 11. The method according to any of Aspects 1-10,
further comprising importing diagnostic data from a third-party
device operably connected to the server and analyzing the data
using the diagnostic data to diagnose causes of the fault.
[0110] Aspect 12. The method according to any of Aspects 1-11,
further comprising acquiring the measured data by one of a
dedicated electronic gathering device operably connected to the
heating, ventilation and air conditioning system, a thermostat in
the heating, ventilation, and air conditioning system, and a
control unit in the heating, ventilation, and air conditioning
system, the server receiving the acquired data in response to a
query from the server.
[0111] Aspect 13. The method according to any of Aspects 1-12,
wherein the fault is a most likely existing fault, wherein
detecting further comprises detecting a plurality of possible
faults in the piece of the equipment based one the data received;
and ranking the plurality of possible faults in ranked order of
most to least likely existing fault in the piece of equipment based
on the data received, wherein the alert generated further includes
the plurality of possible faults and the ranked order.
[0112] Aspect 14. A system for detecting and diagnosing faults in a
heating, ventilation and air conditioning system, the system
comprising: a server, the server being communicatively coupled to a
heating, ventilation and air conditioning system; wherein the
server is configured to: receive data from a plurality of sensors
associated with the heating, ventilation and air conditioning
system, the data including measured data from each of the plurality
of sensors and identifying criteria associated therewith, the
identifying criteria including a location of the sensor associated
with the measured data, at least one of the plurality of sensors
being associated with a piece of equipment in the heating,
ventilation and air conditioning system, the identifying criteria
for the at least one sensor further identifying the piece of
equipment associated therewith; detect a fault in the piece of the
equipment based on the data received; and generate an alert in
response to the fault being detected.
[0113] Aspect 15. The system of Aspect 14, wherein the server is
further configured to calculate a probability of the fault in the
piece of equipment based on the data received; and to generate an
alert in response to the probability of the fault exceeding a
predetermined threshold.
[0114] Aspect 16. The system of Aspects 14-15, wherein the data
includes event data comprising a record of an event and a date and
time of occurrence of the event, and measured data continuously
received at predetermined intervals, the system further comprising
a database operably connected to the server, wherein the server is
further configured to: continuously receive the measured data at
predetermined intervals; aggregate the event data and the
continuously received measured data; calculate the probability of
the fault based on the aggregated data; and store the aggregated
data, the probability calculated, and a record of the alert
generated, in the database.
[0115] Aspect 17. The system of any of Aspects 14-16, wherein the
server is further configured to: collect data associated with one
of a common type of the equipment and a common mode of the
equipment from a plurality of heating, ventilation and air
conditioning systems; and analyze the collected data associated
with the common type or common mode of equipment to determine a set
of rules for calculating the probability of a particular fault
occurring in the equipment associated with the common type or
common mode.
[0116] Aspect 18. The system of any of Aspects 14-17, the server
further configured to: diagnose one or more causes of the fault
based on the data received; and communicate the alert in a fault
notification to one of a user device and a thermostat display.
[0117] Aspect 19. The system of any of Aspects 14-18wherein the
server is operably connected to one of a dedicated electronic
gathering device, a thermostat, and a control unit in the heating,
ventilation, and air conditioning system, wherein the one of the
dedicated electronic gathering device, the thermostat, and the
control unit acquires the data associated with the equipment, the
sever further configured to query one of the dedicated gathering
device, the thermostat and the control unit to forward the acquired
data.
[0118] Aspect 20. A computer-readable device to store instructions
that, when executed by a processing device, cause the processing
device to perform operations comprising:
[0119] receiving data from a plurality of sensors associated with a
heating, ventilation and air conditioning system, the data
including measured data from each of the plurality of sensors and
identifying criteria associated therewith, the identifying criteria
including a location of the sensor associated with the measured
data, at least one of the plurality of sensors being associated
with a piece of equipment in the heating, ventilation and air
conditioning system, the identifying criteria for the at least one
sensor further identifying the piece of equipment associated
therewith; calculating a probability of a fault in the piece of
equipment based on the data received; and generating an alert in
response to the probability of the fault exceeding a predetermined
threshold.
[0120] Aspect 21. The computer-readable device of Aspect 20, the
operations further comprising diagnosing one or more causes of the
fault based on the data received, and communicating the alert as a
fault notification including the one or more causes of the fault to
one of a user device and a thermostat display.
[0121] Aspect 22. A method for detecting and diagnosing faults in a
heating, ventilation and air conditioning system, the method
comprising: receiving, by a server, data from a plurality of
sensors associated with a heating, ventilation and air conditioning
system, the data including measured data from each of the plurality
of sensors and identifying criteria associated therewith, the
identifying criteria including a location of the sensor associated
with the measured data, at least one of the plurality of sensors
being associated with a piece of equipment in the heating,
ventilation and air conditioning system, the identifying criteria
for the at least one sensor further identifying the piece of
equipment associated therewith; calculating, by the server, a
likelihood of occurrence of a fault in the piece of equipment based
on the data received; generating an alert, by the server, of the
fault in response to the likelihood of occurrence exceeding a
predetermined threshold; and transmitting the alert to one of a
user device and a thermostat in the heating, ventilation and air
conditioning system, the alert being viewable on a display
associated with the thermostat.
[0122] Particular embodiments of the present disclosure have been
described herein, however, it is to be understood that the
disclosed embodiments are merely examples of the disclosure, which
may be embodied in various forms. Well-known functions or
constructions are not described in detail to avoid obscuring the
present disclosure in unnecessary detail. Therefore, specific
structural and functional details disclosed herein are not to be
interpreted as limiting, but merely as a basis for the claims and
as a representative basis for teaching one skilled in the art to
variously employ the present disclosure in any appropriately
detailed structure.
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