U.S. patent application number 16/277256 was filed with the patent office on 2019-06-20 for air conditioner mister, apparatus and method.
This patent application is currently assigned to Mistbox, Inc.. The applicant listed for this patent is Mistbox, Inc.. Invention is credited to William S. Nachefski, Joshua Allen Teekell.
Application Number | 20190191595 16/277256 |
Document ID | / |
Family ID | 57504203 |
Filed Date | 2019-06-20 |
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United States Patent
Application |
20190191595 |
Kind Code |
A1 |
Nachefski; William S. ; et
al. |
June 20, 2019 |
Air Conditioner Mister, Apparatus and Method
Abstract
An apparatus includes a mister having an on state and an off
state. A thermostat is coupled to an air conditioner compressor and
to the mister. The thermostat informs the mister when the air
conditioner compressor is running and the mister uses that
information to determine whether to transition between the on state
and the off state.
Inventors: |
Nachefski; William S.;
(Katy, TX) ; Teekell; Joshua Allen; (Houston,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mistbox, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Mistbox, Inc.
Houston
TX
|
Family ID: |
57504203 |
Appl. No.: |
16/277256 |
Filed: |
February 15, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14851146 |
Sep 11, 2015 |
10251316 |
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16277256 |
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14495466 |
Sep 24, 2014 |
9134039 |
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14851146 |
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13482815 |
May 29, 2012 |
9198980 |
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14495466 |
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62174045 |
Jun 11, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 1/42 20130101; B01F
3/04 20130101; F17D 3/01 20130101; F24F 11/56 20180101; F24F 11/30
20180101; F28D 5/00 20130101; F24F 2013/225 20130101; H05K 7/20763
20130101; G05B 15/00 20130101; F24F 11/00 20130101; F24F 2110/00
20180101 |
International
Class: |
H05K 7/20 20060101
H05K007/20; G05B 15/00 20060101 G05B015/00; F17D 3/01 20060101
F17D003/01; F24F 11/00 20060101 F24F011/00; B01F 3/04 20060101
B01F003/04; F28D 5/00 20060101 F28D005/00 |
Claims
1-19. (canceled)
20. An apparatus comprising: a mister having an on state and an off
state; a thermostat coupled to an air conditioner compressor and to
the mister; and wherein the thermostat informs the mister when the
air conditioner compressor is running and the mister uses that
information to determine whether to transition between the on state
and the off state.
21. The apparatus of claim 20 wherein the thermostat is wirelessly
coupled to the mister.
22. An apparatus comprising: a mister having an on state and an off
state; an air conditioner compressor having a fan; and a sensor
coupled to the air conditioner compressor and to the mister,
wherein the sensor detects a difference in light adjacent the air
conditioner compressor when the air conditioner compressor is on
and the fan is spinning versus when it is off and the fan is not
spinning; wherein the mister uses the sensor to determine whether
to transition between the on state and the off state.
23. The apparatus of claim 22 wherein the sensor detects a
difference in the intensity of light adjacent the air conditioner
compressor when the air conditioner compressor is on and the fan is
spinning versus when it is off and the fan is not spinning.
24. The apparatus of claim 22 wherein the fan has blades and the
apparatus further comprises: a mirror coupled to one of the blades
of the fan and positioned so that it will direct light in flashes
to the sensor once per revolution of the fan; and wherein the
sensor detects the once-per-revolution flashes of light.
25. The apparatus of claim 22 wherein the fan has blades and the
sensor detects a difference in the intensity of light adjacent the
air conditioner compressor when a blade of the fan is below the
sensor versus when a blade of the fan is not below the sensor.
26. An apparatus comprising: a mister having an on state and an off
state; an air conditioner compressor having a fan that blows air
outward from the compressor when the compressor is running; and a
generator in the path of the air blown from the compressor, the
generator generating electricity when air of sufficient force is
blowing from the compressor; wherein the mister switches between
the on state and the off state when electricity generated by the
generator reaches a threshold.
27. The apparatus of claim 26 wherein the generator is a fan.
28. The apparatus of claim 26 wherein the mister switches from the
off state to the on state when the electricity generated by the
generator reaches the threshold from below.
29-34. (canceled)
Description
CROSS-REFERENCE TO RELATED
[0001] This application is a divisional of U.S. patent application
Ser. No. 14/851,146, filed Sep. 11, 2015, now U.S. Pat. No. ______,
which is a continuation-in-part of U.S. patent application Ser. No.
14/495,466, filed Sep. 24, 2014, entitled "Air Conditioner Mister,
Apparatus and Method," now U.S. Pat. No. 9,134,039, which is a
continuation-in-part of U.S. patent application Ser. No.
13/482,815, filed May 29, 2012 entitled "Air Conditioner Mister,
Apparatus and Method," now U.S. Pat. No. 9,198,980, all of which
are incorporated by reference. This application claims the benefit
of U.S. Provisional Application No. 62/174,045, filed Jun. 11,
2015, which is incorporated by reference.
BACKGROUND
[0002] The present disclosure relates generally to an apparatus and
method for cooling an air conditioner system in order to boost the
efficiency thereof. In order to better understand the disclosure,
some background on the operation of an air conditioner system may
be helpful.
[0003] Willis Haviland Carrier developed the first modern air
conditioning system in 1902. It was designed to solve a humidity
problem at the Sackett-Wilhelms Lithographing and Publishing
Company in Brooklyn, N.Y. Paper stock at the plant would sometimes
absorb moisture from the warm summer air, making it difficult to
apply the layered inking techniques of the time. Carrier treated
the air inside the building by blowing it across chilled pipes. The
air cooled as it passed across the cold pipes, and since cool air
cannot carry as much moisture as warm air, the process reduced the
humidity in the plant and stabilized the moisture content of the
paper. Reducing the humidity also had the side benefit of lowering
the air temperature, and a new technology was born.
[0004] The actual process air conditioners use to reduce the
ambient air temperature in a room is based on a simple scientific
principle. The rest is achieved with the application of a few
clever mechanical techniques. Air conditioners use refrigeration to
chill indoor air, taking advantage of a physical law-when a liquid
converts to a gas (in a process called phase conversion), it
absorbs heat. Air conditioners exploit this feature of phase
conversion by forcing special chemical compounds to evaporate and
condense over and over again in a closed system of coils.
[0005] The compounds involved are refrigerants that have properties
enabling them to change at relatively low temperatures. Air
conditioners also contain fans that move warm interior air over
these cold, refrigerant-filled coils. In fact, central air
conditioners have a whole system of ducts designed to funnel air to
and from these serpentine, air-chilling coils.
[0006] When hot air flows over the cold, low-pressure evaporator
coils, the refrigerant inside absorbs heat as it changes from a
liquid to a gaseous state. To keep cooling efficiently, the air
conditioner has to convert the refrigerant gas back to a liquid
again. To do that, a compressor puts the gas under high pressure,
which is a process that creates unwanted heat. All the extra heat
created by compressing the gas is then evacuated to the outdoors
with the help of a second set of coils called condenser coils, and
a second fan. As the gas cools, it changes back to a liquid, and
the process starts all over again. The process can be thought of as
an endless cycle: liquid refrigerant, phase conversion to a gas,
heat absorption, compression, and phase transition back to a liquid
again.
[0007] The major parts of an air conditioner manage refrigerant and
move air in two directions: indoors and outside. The parts consist
of:
[0008] Evaporator--Receives the liquid refrigerant;
[0009] Condenser--Facilitates heat transfer;
[0010] Expansion valve--regulates refrigerant flow into the
evaporator;
[0011] Compressor--A pump that pressurizes refrigerant.
[0012] The cold side of an air conditioner contains the evaporator
and a fan that blows air over the chilled coils and into the room.
The hot side contains the compressor, condenser, and another fan to
vent hot air coming off the compressed refrigerant to the outdoors.
In between the two sets of coils, there typically is an expansion
valve. It regulates the amount of compressed liquid refrigerant
moving into the evaporator. Once in the evaporator, the refrigerant
experiences a pressure drop, expands, and changes back into a gas.
The compressor typically is an electric pump that pressurizes the
refrigerant gas as part of the process of turning it back into a
liquid. There are some additional sensors, timers and valves, but
the evaporator, compressor, condenser, and expansion valve are the
main components of an air conditioner.
[0013] Most air conditioners have their capacity rated in British
thermal units (Btu). A Btu is the amount of heat necessary to raise
the temperature of 1 pound (0.45 kilograms) of water one degree
Fahrenheit (0.56 degrees Celsius). One Btu equals 1,055 joules. In
heating and cooling terms, one ton equals 12,000 Btu.
[0014] A typical window unit air conditioner might be rated at
10,000 Btu. For comparison, a typical 2,000-square-foot (185.8
square meters) house might have a 5-ton (60,000-Btu) air
conditioning system, implying that a person might need perhaps 30
Btu per square foot. These are rough estimates. The energy
efficiency rating (EER) of an air conditioner is its Btu rating
over its wattage. As an example, if a 10,000-Btu air conditioner
consumes 1,200 watts, its EER is 8.3 (110,000 Btu/1,200 watts).
Obviously, one would like the EER to be as high as possible, but
normally a higher EER is accompanied by a higher price.
[0015] The following example helps illustrate the process of
selecting the most economical/efficient air conditioning system.
Suppose you have a choice between two 10,000-Btu units. One has an
EER of 8.3 and consumes 1,200 watts, and the other has an EER of 10
and consumes 1,000 watts. Suppose also that the price difference
between the two units is $100. To determine the payback period on
the more expensive unit, you need to know approximately how many
hours per year you will be operating the air conditioner and how
much a kilowatt-hour (kWh) costs in your area. Assume you plan to
use the air conditioner six hours a day for four months of the
year, at a cost of $0.10/kWh. The difference in energy consumption
between the two units is 200 watts. This means that every five
hours the less expensive unit will consume one additional kWh (or
$0.10) more than the more expensive unit.
[0016] With roughly 30 days in a month, you are operating the air
conditioner:
4 months.times.30 days per month.times.6 hours per day=720
hours
[(720 hours.times.200 watts)/(1000
watts/kilowatt)].times.$0.10/kilowatt hours=$14.40
[0017] The more expensive air conditioning unit costs $100 more to
purchase but less money to operate. In our example, it will take
seven years (7.times.$14.40=$100.80) for the higher priced unit to
break even. Because of the rising costs of electricity and a
growing trend to "go green," more people are turning to alternative
cooling methods to spare their pocketbooks and the environment.
Nevertheless, as the above description shows, substantial savings
can also be had by increasing the efficiency of an existing air
conditioner unit. One way of doing that is by employing the method
and apparatus of the present invention, which uses less energy to
achieve the same or greater performance.
SUMMARY OF THE INVENTION
[0018] The present disclosure provides an alternative to the
ever-increasing cost of electricity and the corresponding cost
burden of using an air conditioner. As described in more detail
below, the present disclosure reduces the amount of energy needed
to condense the refrigerant on the hot side of the air conditioning
system. Specifically, the present disclosure provides a novel
system for spraying a mist of water on the air conditioner's
condensing coils so that, as the water hits the coils and
evaporates, it reduces the temperature of the coils. This reduced
temperature assists in more rapidly reducing the temperature of the
refrigerant inside the condenser and more rapidly enables the
refrigerant to change from a gas to a liquid. The more rapidly this
process takes place, the less electricity needed (by the
compressor, fan, etc.) to complete that process. The less
electricity needed, the less the cost to run the system. Likewise,
the less the compressor and fan are required to run to do their
job, the longer they will last and not need to be replaced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a plan view of a misting system including a supply
hose, controller, filter and manifold.
[0020] FIG. 2 is a plan view of a control box
[0021] FIG. 3 is a cross-sectional view of a filter.
[0022] FIG. 4 is a plan view of a manifold.
[0023] FIG. 5 illustrates control inputs used for controlling a
misting system.
[0024] FIG. 6A is a cross-sectional view of an adjustable
manifold.
[0025] FIG. 6B is an exploded view of one end of an adjustable
manifold.
[0026] FIG. 6C is a plan view of an adjustable manifold.
[0027] FIG. 6D is plan view of daisy-chained adjustable
manifolds.
[0028] FIG. 6E is a plan view of a final adjustable manifold in
daisy-chained adjustable manifolds.
[0029] FIG. 6F is a cross-sectional view of an air bleeding check
valve.
[0030] FIG. 7 is a block diagram of a wireless misting
controller.
[0031] FIG. 8 is a block diagram of a wireless misting
controller.
[0032] FIG. 9 is a block diagram of a misting system with wireless
communication.
[0033] FIG. 10 is a block diagram of multiple misting systems
interacting with a cloud based server.
[0034] FIG. 11 is a perspective view of a box
[0035] FIG. 12 is a cross-sectional view of the box of FIG. 11.
[0036] FIG. 13 is a block diagram of the misting system with a box
interacting with a cloud based server.
[0037] FIG. 14 is block diagram of multiple misting systems with
boxes interacting with a cloud based server.
DETAILED DESCRIPTION
[0038] The following detailed description illustrates embodiments
of the present disclosure. These embodiments are described in
sufficient detail to enable a person of ordinary skill in the art
to practice these embodiments without undue experimentation. It
should be understood, however, that the embodiments and examples
described herein are given by way of illustration only, and not by
way of limitation. Various substitutions, modifications, additions,
and rearrangements may be made that remain potential applications
of the disclosed techniques. Therefore, the description that
follows is not to be taken as limiting on the scope of the appended
claims. In particular, an element associated with a particular
embodiment should not be limited to association with that
particular embodiment but should be assumed to be capable of
association with any embodiment discussed herein.
[0039] Referring initially to FIG. 1, a misting system 5 is
illustrated. The misting system 5 may include a first supply hose
10, a control box 20, a filter 30, a second supply hose 40, and a
manifold 50. The first supply hose 10 may be constructed from 1/2
inch vinyl tubing and connects to a water supply source (not shown)
at a first end and to an input on control box 20 at a second end.
The control box 20 may house a solenoid valve 25 and circuitry (not
shown) programmable to control operation of the misting system 5.
The first end of filter 30 connects to an output of control box 20,
whereas a second end of filter 30 connects to a first end of second
supply hose 40. The supply hose 40 may be constructed from 1/4 inch
vinyl tubing. A second end of supply hose 40 may connect to
manifold 50.
[0040] Referring to FIG. 2, the control box 20 is illustrated. As
shown, the control box 20 may include an input 22, an output 24, a
button selector 28, and an LCD view screen 26. Control box 20 may
also include a port for receiving an electrical signal and/or an
antenna for receiving a wireless signal where, as described in more
detail below, the received signal(s) can be used to control the
programming and/or operation of control box 20.
[0041] Referring to FIG. 3, the filter 30 is illustrated. As shown,
the filter 30 may include an input 32 and an output 34.
[0042] Referring to FIG. 4, the manifold 50 is illustrated. As
shown, the manifold 50 may include an input 52, an output 54, and a
spray nozzles 56. While three spray nozzles 56 are depicted,
different numbers can be chosen depending on the need for the
particular application.
[0043] The misting system 5 depicted in FIG. 1 may operate as
follows. The first end of supply hose 10 is connected to a water
source (not shown), such as a water faucet on the exterior of a
home. When the water supply is turned on, water flows from the
source, through the first supply hose 10, and into the control box
20. The control box 20 may include a solenoid valve 25 that opens
and closes under the program control of the control box 20. When
the solenoid valve 25 is closed, no water flows through the control
box 20. When the solenoid valve 25 is open, water flows through the
control box 20 and into the filter 30.
[0044] As will be described in more detail below in connection with
FIG. 3, the filter 30 softens the water flowing there-through so as
to reduce mineral build-up in the second supply hose 40, the
manifold 50, and on any surface in the air conditioner unit that
gets wet as a result of using the apparatus. Locating the filter 30
on the downstream side of the control box 20 means that it is not
under constant water pressure, as it would be if it were located on
the upstream side of control box 20. This may extend the life of
the filter 30.
[0045] Next, as water flows through the filter 30 and the second
supply hose 40, it enters the manifold 50. The water at this point
is under pressure from its supply and the reduced diameter of the
second supply hose 40. Other methods may be used for adjusting the
pressure of the water supplied to the manifold 50. Water enters the
manifold 50 and exits, under pressure, through the spray nozzles
56. The manifold 50 is positioned on the air conditioner system so
that the exiting water spray primarily falls on the air
conditioner's condenser. As explained above, this water and its
evaporation cool the condenser, thereby aiding in the cooling of
the refrigerant inside, and reducing the time/power necessary to
cool the refrigerant.
[0046] As will be appreciated by those skilled in the art, one or
more manifolds 50 can be employed depending on the configuration
desired. For example, a single manifold 50 can be used on one side
of the air conditioner unit. Alternatively, additional manifold
units 50 can be connected together by uniting them at their
inputs/outputs shown in FIGS. 4, 5A-5C (discussed below). For
example, using four manifold units 50 would enable a user to place
one manifold 50 on each of the four sides of an air conditioner so
that the water spray would enter the air conditioner from all
sides. Depending on the configuration, this may add to the volume
of water falling on the condenser inside the air conditioner unit.
Likewise, more than one manifold unit 50 could be placed on the
same side of the air conditioner if that proved to be the best way
of misting the condenser.
[0047] In or more embodiments, a drain (not shown) is added to the
valve between the filter 30 and the manifold 50. This drain valve
would open when the misting system 5 is not on in order to drain
water from manifold 50, the second supply hose 40, and the filter
30.
[0048] The time that the misting system 5 operates may also be
important. For example, no water should be flowing if the air
conditioner unit is not running. Control of the water supply is
managed by programmable circuitry inside control box 20 (in order
to open/close the solenoid valve 25) with the aid of one or more of
the inputs/metrics shown in FIG. 5, as discussed below.
[0049] The control box 20 may house a central processing unit (CPU)
505 that operates under program control. In one embodiment, the CPU
505 uses three sources of information to decide when to initiate
(i.e., open) the solenoid valve 25. The CPU 505 receives
information from an electromagnetic field (EMF) detector 510, which
measures electromagnetic fields generated by the compressor's
induction motor, an acoustic detector 515, which measures acoustic
levels, and a temperature sensor 520, which measures the ambient
temperature near the control box 20. All three measurements are
amplitude based. Because the apparatus typically is either full on
or full off, it typically only cares about peak amplitudes of each
metric. The CPU 505 uses the measured data to determine when to run
the misting system 5.
Temperature
[0050] Water based pre-cooling begins to lose efficiency the closer
the water temperature is to the ambient temperature. Tests have
shown 78 degrees Fahrenheit to be the best all around temperature
based cutoff. Thus, in this embodiment, if the temperature sensor
520 reads less than a threshold, such as 78 degrees Fahrenheit, the
CPU 505 will sense that and disable the unit (i.e., it will not
allow the solenoid valve 25 to open).
Acoustics
[0051] The acoustics section uses the amplitude of the sound waves
generated by the running compressor and fan as a turn-on
verification. When a predetermined appropriate noise threshold is
met (as sensed by the acoustic detector 515 and delivered to the
CPU 505), the CPU 505 will allow the misting system 5 to arm (i.e.,
capable of turning on the solenoid valve 25 if other parameters are
met). This is a method the CPU 605 uses to confirm the compressor
is running. As indicated, having this threshold met alone will not
turn the misting system 5 on, it is used merely as a "go, no go"
signal to the CPU 505.
Electromagnetic Field/Compressor Current Detection
[0052] When the compressor motor turns on, it generates strong EMF
around its core. The CPU 505 is equipped with an antenna system
(EMF detector 510 in FIG. 5) designed to pick up and measure these
fields. Using EMF to gauge operation allows the unit to
discriminate between local AC systems (when the misting system 5 is
installed on multiple compressor systems) as well as tell the CPU
505 when it is the proper time to turn on the misting system 5. The
misting system 5 preferably should only run when the compressor is
on.
[0053] Accordingly, in this embodiment, the CPU 505 senses
temperature, acoustics, and EMF. The CPU 505 will only cause the
solenoid valve 25 to open if each of these metrics is met. In other
words, in this particular embodiment, the solenoid valve 25 will
open if the ambient air temperature is at least 78 degrees
Fahrenheit, the acoustic detector 515 detects a sufficient level of
"noise", and the EMF detector 510 detects a sufficient level of
EMF. If all three of these metrics are met, the CPU 505 will issue
a command to open the solenoid valve 25 and allow water to traverse
the solenoid valve 25 and ultimately mist the air conditioner unit.
If any one of these metrics are not met, the CPU 505 will not open
the solenoid valve 25, thereby preventing any water from traversing
the valve.
[0054] In yet another embodiment, the CPU 505 can receive a wired
or wireless input signal that further controls (or assists in the
control of) the solenoid valve 25. In this embodiment, for example,
the received/input signal could be activated, thereby telling the
CPU 505 to (1) either override the other inputs and open (or close)
the solenoid valve 25 or (2) operate as another input for the
controller to consider when deciding to open (or close) the
solenoid valve 25. The wired input signal can emanate from any
source, such as a manual or programmable on/off switch, a home
automation system, a thermostat, an alarm system, etc. Similarly,
the wireless input signal can be generated by receipt of a wireless
signal from any source, such as an IEEE 802.11 or a Bluetooth
compliant signal delivered by any device capable of communicating
using either standard. For example, the state of the input signal
could be controlled by a handheld remote control, or a web or
mobile application that allows its user to activate the input
signal in order to control (or assist the control of) the solenoid
valve. In the case of web or mobile applications (as with an
appropriate hard-wire signal), they could also be designed to
enable the user to reprogram the CPU 505 to open/close the solenoid
valve 25 based on a different combination of inputs than the
combinations described above.
[0055] Those skilled in the art will appreciate that other metrics
can be used, including more, less, and/or different metrics.
Likewise, variants of the preferred components of the misting
system 5, as described below, are within the scope of the present
disclosure.
Manifold
[0056] The misting system 5 may include a plurality (e.g., three)
of manifolds 50, each with three mister nozzles 56 attached. The
nozzles 56 are rated for 5.4 gph @ 80 psi and have an orifice of
0.04 mm. While the manifold 50 can be any shape, the manifold may
have a flat side to host the nozzles 56. A flat surface enables a
nozzle o-ring (not shown) to properly seat between the nozzle 56
and the side, so as to best prevent water leakage and provide
optimal spray out of the nozzle. Additional manifolds 50 can be
added, as can manifolds 50 with more (or less) mister nozzles
attached. As will be appreciated by those skilled in the art, as
mister nozzles 56 are added, the flow rate increases.
Filters
[0057] The filter 30 may be made by Electrical Appliances Ltd. In
one or more embodiments, the filters are standard 10''.times.2''
cylindrical cartridge filters 30 often seen on ice makers. The
filters 30 may have 1/2'' national pipe thread (npt) ports and are
made of low density (LD) polyethylene. In one or more embodiments,
the filtration media is Sodium Polyphosphate. Siliphos (for short)
is a crystal-based media that dissolves slowly as water passes over
it. When dissolved, its molecules prevent iron, calcium, magnesium
(the constituents of water scale) from forming residue that could
clog the misting system 5 as well as damage the air conditioner's
cooling system.
Valve
[0058] As described above, the solenoid valve 25 is the heart of
the CPU's 505 control of the misting system 5 because it controls
when the water flows to the manifold 50. A person of ordinary skill
would understand that solenoid valve 25 could be replaced by a
different kind of valve (e.g., an electrically operated ball
valve). In embodiments where the misting system 5 is solar powered
(using the solar array 525 as shown in FIG. 5), a special
consideration is how much power the valve consumes. Traditional
solenoid valves do not work well because they require power to be
constantly applied to stay open. For example, the valve may use a
22 millisecond (ms)+/-10% positive polarity pulse to latch the
valve open and a 44 ms+/-10% negative polarity pulse to latch the
valve closed. No other power is required to keep the valve open
after the initial open signal is sent. When it is time to close the
valve, a short negative going pulse is applied to the solenoid
valve 25 and it latches closed.
Batteries
[0059] In one or more embodiments, batteries 530 (as illustrated in
FIG. 5) are standard AA 1.5V nominal at 2,500 mAH units. If a solar
array is used, the standard AA batteries are replaced by a
rechargeable battery pack. In one or more embodiments, four
batteries 530 typically are required for operation, and with the
solar array trickle 525 charging the pack during daylight hours,
the battery pack will last at least six months without needing to
be replaced.
User Interface
[0060] In one or more embodiments, interfacing with the misting
system 5 is achieved via one ductile weather proof rubberized push
button switch (such as button selector 28, see FIG. 2) mounted on
the exterior of the control box 20 (see FIG. 2) and a piezo speaker
535 located within the control box 20 (see FIG. 5). Using a system
of button pushes and audio feedback, the user can set up the
misting system 5. Other embodiments of the disclosure can use more
push buttons for added functionality. In one or more embodiments,
the misting system 5 can be set up remotely by way of a mobile
device or a cloud based system as described below.
Solar Array
[0061] In one or more embodiments, the solar array 525 is a 9 Volt
(V) 200 milliampere (ma) crystal metal matrix solar array 525 that
helps keep the batteries 530 topped off and extends the misting
system's autonomous run time. The CPU 505 may have battery
management/solar charger software installed, and it handles the job
of battery pack maintenance and charging via solar energy.
CPU
[0062] In one or more embodiments, the CPU 505 is an 8-bit
microcontroller (e.g., the ATtinymega88 series provided by Atmel).
All functions of the controller are encoded and controlled via
software. This not only allows for precision when it comes to
control, measurements, and management, but it also lends itself to
future proofing of the misting system 5. During the lifetime of the
product, it may be desirable to fine tune and make changes to the
control architecture and protocol of the misting system 5. Because
the control box 20 preferably has a programming port (not shown),
that enables updates of previously manufactured systems to current
firmware.
[0063] In one or more embodiments, during initial set up, the
misting system 5 needs to be calibrated to the specific compressor
system that it is installed on. Calibration ensures that the
misting system 5 function is tailored to each individual
installation. Upon initial assembly and set up, the unit is powered
on with the control button (see button selector 28 in FIG. 2)
depressed. After 5 seconds, the control box 20 is programmed to
enter calibration mode. The control box 20 will stay in the
calibration mode until told otherwise. When the compressor turns
on, the CPU 505 will, in one or more embodiments, set its
thresholds within approximately 10 seconds. When the CPU 505 has
enough information to set the proper thresholds, it will beep
twice. The user then presses and holds the control button (such as
button selector 28) for 5 seconds and the thresholds become stored
in memory (not shown) and the setup mode is exited. A successful
calibration will result in the control box 20 making a series of
beeps. The beeps will last 5 seconds allowing the user to back away
from the control box 20 before it begins misting. Thereafter, the
CPU 505 will run its normal program. A filter timer is initialized
and started, and the misting system 5 will function autonomously
until the filter timer reaches 0.
[0064] When it is time to change the filter cartridge (i.e., when
the filter timer reaches 0), the misting system 5 is programmed to
alert the user via a series of audible beeps that run for 5 seconds
every other hour (only during the day). When the user is ready to
make the filter 30 change, they will turn off the water source and
disconnect the hose 40 from the input port 22. The control button
28 is pressed and held for 5 seconds. The control box 20 will make
a series of beeps to let the user know it is now in standby mode
and is OK to change the filter 30. The user removes the old filter
30 by unscrewing it from the control box 20 and replaces it with a
new filter 30. Once the water source is reconnected and turned on,
the user presses and holds the control button 28 for 5 seconds. The
control box 20 responds by emitting a series of beeps and the main
program begins to run. The filter timer is also reset.
Adjustable Manifold
[0065] The manifold 505 can be replaced by an adjustable manifold
605, as illustrated in FIGS. 6A-6C. The adjustable manifold 605 may
include a manifold body (or housing) 610. The manifold body 610 may
have an inside diameter that traverses the length of the manifold
body 610. The manifold body 610 may include a tubing end 615 and a
coupling end 620. In one or more embodiments, the tubing end 615 is
integral with a tubing-end shoulder 625. In one or more
embodiments, the coupling end 620 is integral with a coupling end
shoulder 630.
[0066] In one or embodiments, the tubing-end shoulder 625 has an
outside diameter larger than the outside diameter of the tubing-end
615. In one or more embodiments, the tubing-end shoulder 625 has an
inside diameter that is larger than the inside diameter of tubing
end 615. A tubing-end funnel 635 is formed by this
configuration.
[0067] In one or embodiments, the coupling-end shoulder 630 has an
outside diameter that is larger than the outside diameter of the
coupling end 620. In one or more embodiments the coupling-end
shoulder 630 has an inside diameter that is smaller than the inside
diameter of the coupling end 620. A coupling-end funnel 640 is
formed by this configuration.
[0068] In one or more embodiments, the adjustable manifold 605
includes a 1/4'' tube 645. The 1/4'' tube 645 has an outside
diameter that is smaller than the inside diameter of the manifold
body 610, which produces a water clearance 650 where water can flow
between the inside diameter of the manifold body 610 and the
outside diameter of the 1/4'' tube 645 to the spray nozzles 56. In
one or more embodiments, the 1/4'' tube 645 has an inside diameter
that traverses the length of the 1/4'' tube 645.
[0069] In one or more embodiments, the adjustable manifold 605 may
include a tubing-end O-ring 655 and a coupling-end O-ring 660. In
one or more embodiments, the tubing-end O-ring 650 may sealingly
abut against the tubing-end funnel 635. In one or more embodiments,
the coupling-end O-ring 660 may sealingly abut against the
coupling-end funnel 640.
[0070] In one or more embodiments, the adjustable manifold 605 may
include a tubing end insert bushing 665. In one or more
embodiments, the tubing end insert bushing 665 has an outside
diameter that is smaller than the inside diameter of the tubing-end
shoulder 625. The tubing end insert bushing 665 may have outside
diameter larger than the manifold body 610 inside diameter. In one
or more embodiments, the tubing end insert bushing 655 has an
inside diameter that traverses the length of the tubing end insert
bushing 665. In one or more embodiments, the inside diameter of the
tubing end insert bushing 665 is larger than the 1/4'' tubing
645.
[0071] In one or more embodiments, a tubing end collet 670 is
couplable to the tubing end insert bushing 655. In one or
embodiments, the tubing end collet 670 has an inside diameter that
is larger than the outside diameter of the 1/4'' tube 645. When
assembled as shown in FIG. 6C, the tubing end collet 670 engages
the 1/4'' tube 645 and secures it to the tubing end insert bushing
665 in such a way that the 1/4'' tube 645 can slide inside the
tubing end collet 670 and the tubing end insert bushing 665. The
tubing end insert bushing 665 engages with the tubing end shoulder
625 and the tubing-end O-ring 655 to seal the water clearance 650
at the tubing end 615 of the manifold body 610.
[0072] In one or more embodiments, the adjustable manifold 605 may
include a coupling end insert bushing 675. In one or more
embodiments, the coupling end insert bushing 675 has an outside
diameter that is smaller than the inside diameter of the
coupling-end shoulder 630. The coupling end insert bushing 675 may
have outside diameter larger than the manifold body 610 inside
diameter. In one or more embodiments, the coupling end insert
bushing 675 has an inside diameter that traverses the length of the
coupling end insert bushing 675. In one or more embodiments, the
inside diameter of the coupling to end insert bushing 675 is larger
than the 1/4'' tubing 645.
[0073] In one or more embodiments, a coupling end collet 680 is
couplable to the coupling end insert bushing 675. In one or
embodiments, the tubing end collet 680 has an inside diameter that
is larger than the inside diameter of the 1/4'' tube 645. When
assembled as shown in FIG. 6C, the tubing end collet 670 engages
the coupling end insert bushing 675, which in turn engages with the
coupling end shoulder 630 and the coupling-end O-ring 660 to seal
the water clearance 650 at the coupling end 620 of the manifold
body 610.
[0074] The tubing end collet 670 includes teeth 685 (the teeth for
the coupling end collet 680 are not labeled to avoid cluttering
FIGS. 6A, 6B, and 6C) that normally engage the 1/4 '' tube 645. The
teeth 685 allow the 1/4'' tube 645 to be pushed into the adjustable
manifold 605 but prevent the 1/4'' inch tube 645 from being pulled
out of the adjustable manifold 605. When the tubing end collet 670
is pressed in (i.e., toward the tubing end insert bushing 665) the
teeth 685 are disengaged from the 1/4'' tube 645, which allows the
1/4'' tube to be pulled out of the adjustable manifold 605.
[0075] The adjustable manifold 605 is shipped with the 1/4'' tube
645 withdrawn inside the manifold body 610. At installation, the
adjustable manifold is coupled to the outside of the compressor as
described above and the 1/4'' tube is extended to mate with the
filter 30 as shown in FIG. 1.
[0076] Multiple adjustable manifolds 605 can be daisy-chained
together, as shown in FIG. 6D. A 1/4'' tube 687 from a second
adjustable manifold 605 is inserted into the coupling end collet
680. As a result of this installation, the first adjustable
manifold and the second adjustable manifold are pressurized by the
water supply. Additional adjustable manifolds 605 can be added. In
one or more embodiments, 4 adjustable manifolds 605 are provided,
one for each side of the compressor.
[0077] The final adjustable manifold 605 in the chain of adjustable
manifolds 605 is illustrated in FIG. 6E. It includes an air
bleeding check valve 690, which is illustrated in more detail in
FIG. 6F.
[0078] The air bleeding check valve 690 includes an insert sleeve
691 that has the same outside diameter as the 1/4'' tube 645 and an
inside diameter sufficient to allow the passage of air and water.
The air bleeding check valve 690 further includes a valve body 692
that is integral with the insert sleeve 691 and includes a chamber
693 with an inside diameter larger than the inside diameter of the
insert sleeve 691. The air bleeding check valve 690 further
includes an outlet port 694 that is integral with the valve body
692 and has an inside diameter smaller than the inside diameter of
the chamber 693. The interface between the valve body 692 and the
outlet port 694 forms two shoulders: an O-ring shoulder 695 and a
spring shoulder 696. A check valve O-ring 697 sealingly abuts the
O-ring shoulder 695. A cylindrical piston 698 is located in the
chamber 693 and moves within the chamber 6933. A spring 699 abuts
the cylindrical piston 697 at one end and the spring shoulder 696
at the other end.
[0079] The cylindrical piston 698 does not fill the entire inside
diameter of the chamber 693. As a result, air will pass around the
cylindrical piston 698 and escape through the outlet port 694.
Water flowing through the air bleeding check valve 690 will escape
around the cylindrical piston 698 and through the outlet port 694
until the water pressure in the chamber 693 exerted on the
cylindrical piston 698 is sufficient to compress the spring 699 to
the point where the cylindrical piston 698 seals against the check
valve O-ring 697. At that point, the air bleeding check valve 690
acts as a plug.
[0080] As a consequence, when the solenoid valve 25 is first turned
on, allowing water to flow to the adjustable manifold 605, any air
present in the system will escape through the air bleeding check
valve 690. When water reaches the air bleeding check valve 690, the
air bleeding check valve 690 closes, causing all adjustable
manifolds 605 in the chain to pressurize and spray water through
their respective spray nozzles 56.
[0081] In one or more embodiments, a filter check valve similar to
the air bleeding check valve 690 is installed on the output 34 of
the filter 30. The difference is the filter check valve has a tee
from the valve body 692 allowing water to continue into the second
tubing when the cylindrical piston 698 seals on the check valve
O-ring 697. This allows a short flow of water through the valve in
the time that the spring 699 is being compressed by the cylindrical
piston 698 so that no water that is oversaturated with filtration
media can continue into the tubing and manifolds potentially
causing clogs.
[0082] When the system turns misting off and there is no water
pressure, water in the 1/4'' tubings 645 and adjustable manifolds
605 drains out of either the air bleeding check valve 690 or the
filter check valve, whichever is closer to the ground.
Wireless Misting Controller
[0083] A wireless misting controller 705 is shown in FIGS. 7 and 8.
The wireless misting controller 705 consists of a microprocessor
based controller (or CPU 710, which may be a microprocessor as
shown in FIG. 8) loaded with a programmed algorithm with adjustable
variables, whose purpose is to take in various sensor inputs
(electromagnetic/current (EM/I) 715, acoustic 720, temperature 725,
pressure 730, current in and out (Iin/Iout) 735, wifi 740 (to
receive, for example, current and/or forecast weather information)
to compute the appropriate misting program and execute it to
control the solenoid valve 25. The wireless misting controller 705
also tracks and stores all runtime data, incoming sensor input data
as well as the results of various calculations from such data. This
data is stored locally on the wireless misting controller 705 in a
log 805 and is periodically transmitted via wifi link 745 to a
cloud based server (described below in connection with FIGS. 9, 10
and 13) where the data is used for computing reports, making
adjustments to the program variables and interacting with the
customer (i.e., by providing alerts). Local program variables can
be changed by the cloud based server to help the local wireless
misting controller 705 learn or optimize its operation. Savings
reports generated by the server side computations may be pushed to
the customer via smart phone APP or web interface. A jack 810 may
be included to allow use of external power and may also be used to
update firmware.
[0084] Installation of the misting system 5 and the wireless
misting system 705 is benign. It requires no wiring or professional
plumbing to make it work, it acquires all of its telemetry data via
wireless sensor interaction with the condenser unit, meaning it
gathers all required telemetry by just being in the vicinity of the
AC condenser. The system is delivered to the customer pre-assembled
and tested. All the customer needs to do, to install a misting
system 5, is to hang the control box 20 or the wireless misting
controller 705 and the manifold(s) 50 and tighten a garden
hose.
Electromagnetic Field/Compressor Current Detection
[0085] The control box 20 and wireless misting controller 705 have
an ultra-sensitive, 3 axis magnetic field detection system that
allows the onboard microprocessor to receive and measure the
magnetic field being transmitted by the compressor motor and/or fan
motor while running. On board circuitry can remove or filter the
50-60 hz component and deduce a proportional voltage to the current
running through the compressor motor. This voltage value is then
passed to the CPU's 710 on board analog to digital converter (ADC)
and output to its registers in a 0-2000 count format. This count
value is used to determine magnitude for turn on events as well as
current calculations via lookup tables in the CPUs 710
registers.
Acoustic Level Detection
[0086] The control box 20 and wireless misting controller 705 have
a sensitive microphone and associated amplification and filtering
circuitry that allow it to listen for and measure the specific
50-60 hz noise created by the compressor and its fan during
operation. The analog voltage level produced by this circuit is
sent to the CPU's 710 ADC and output to its registers in a 0-1000
count format. This count value is used to determine magnitude to
confirm a turn on event.
Temperature Input
[0087] On board temperature sensor allows the control box 20 and
wireless misting controller 705 to decide when it is warm enough to
run a misting program. The input from this sensor is weighed within
a mist program algorithm executed by the CPU 710. Allowable
temperature ranges are controlled via real time interaction with
the cloud based server (discussed below).
Charge Sensing (Iin/Iout)
[0088] With the main power source being solar it is useful to keep
track of the energy storage system's status as well as knowing if
there is a power deficit. The CPU 710 tracks the amount of current
going into the battery pack as well as the amount going out to get
a an overall picture of the power system's general health. There
are preprogrammed fail safes built into the system that will force
the computer into a self-preservation mode, disabling all wife
communications but continuing misting operation, until battery
levels can be replenished. This way all misting functionality is
maintained even if the wireless link needs to be severed due to
power concerns. This power in vs power used will be shown
graphically to the customer via an application that runs on a
mobile device or a computer ("APP"). This data can help tailor
their use of the "APP".
Wifi Connectivity
[0089] Other remote devices can connect with the control box 20 or
wireless misting controller 705 to either tell it to turn on/off or
change various program parameters via reprogramming. The control
box 20 and wireless misting controller 705 are also able to
transmit reports of all stored data to cloud based servers
(described below in connection with FIGS. 9, 10, and 12) for data
extrapolation and the creation of reports for the customer to
utilize in the provided "APP". The control box 20 and wireless
misting controller 705 store all telemetry and runtime data for a
24 hour period, once this 24 hour buffer is filled with data,
control box 20 and wireless misting controller 705 will make
connection with a cloud based server (described below in connection
with FIGS. 9, 10, and 12) and send the report, where it will be
logged to that specific account and used to quantify savings,
etc.
Pressure Sensor
[0090] A pressure sensor may be located at the inlet to the
solenoid valve 25, which allows incoming pressure as well as
functional pressure drop to be measured by the CPU 710. This sensor
uses a relative type of measurement scale, meaning that the CPU 710
will decide what the normal baseline pressure reading is and send
alarms should pressures fall below certain preset operational
thresholds.
Alarms
[0091] In the event of freezing weather or a pressure drop in the
system (due to leaks or catastrophic failure) the control box 20
and wireless misting controller 705 will send an alert signal to
the cloud based servers (described below in connection with FIGS.
9, 10, and 12) which will then contact the customer via the "APP"
to alert them of a possible problem. In the event of a detected
downstream leak the CPU wills cease operation until action is
taken.
Disable/Enable
[0092] A user is able to turn on or turn off the misting function
at any time via the APP. When this selection is made our servers
will contact that particular control box 20 and wireless misting
controller 705 and disable/enable misting.
Valve
[0093] Due to low power requirements, the misting system 5 utilizes
a low power latching type piloted solenoid valve. A small 2 mS
positive going pulse opens the valve while a 2 mS negative going
pulse closes the valve.
[0094] Because the valve stays in a steady state once a pulse a
received no other power is used keeping it open or close. Negative
and positive pulses are provided by the microprocessor and are
buffered via an H bridge of mosfets.
Low Power
[0095] Because control box 20 and wireless misting controller 705
is battery/solar operated, power use is carefully monitored.
Without the wifi transceiver requirements the system utilizes a few
nano amps to function. Care was taken during circuit design to
minimize drain currents, leakage, and IC power consumption. All
systems are gated via high side mosfet and are switched on only
when needed. The control box 20 and wireless misting controller 705
spends most of its time in a sleep state, waking all systems once
every .about.2 seconds for a period of 100 ms then returning to
sleep. This topology ensures extremely low power consumption and
allows the product to subsist on very low recharge rates.
Preassembly and Adjustability
[0096] All systems are assembled and pretested prior to being
shipped to the customer. The customer can adjust tube length on the
manifold system without compromising the factory tested seal .
Adjustments are made by pushing in the locking tubing end collet
670 while pulling out the 1/4'' tube 645 to desired length, as
described above in connection with FIGS. 6A, 6B, and 6C. This is
accomplished by utilizing a specially designed radial sealing/feed
system in the manifold design that allows a large length of 1/4''
tube 645 to be passed through it while retaining flow to all
nozzles 56 in its path. The locking tubing end collet 670 ensures
once the length is adjusted it will stay constant.
Mistbox Algorithm
Introduction
[0097] To minimize water consumption while maximizing power
savings, control box 20 and wireless misting controller 705 use a
number of criteria to determine when misting should occur. The
process effectively trades water for energy, which can be
beneficial monetarily for a homeowner. However, air-cooled air
conditioning systems are only inefficient in certain cases. While
misting continually would fully minimize power consumption, such
operation would be very wasteful where water is concerned. Also,
even misting only when the AC system is running can produce
situations with extreme diminishing returns. Thus, to fully
optimize the system and maximize savings, an algorithm takes into
account a number of different criteria to decide when misting
should take place.
Algorithm Variables
[0098] 1. Whether the AC system is running. Not only should the fan
be running, but the system should be in a cooling cycle or else
cooling the intake air will have no benefit. To accomplish
determining whether the condenser unit is running or not, the
control box 20 and wireless misting controller 705 measure the
following metrics.
[0099] A. Electromagnetic field strength to indicate whether the
compressor motor is running;
[0100] B. Vibration to determine whether the fan is in operation;
and
[0101] C. Acoustic (sound) to determine whether the fan and motor
are running.
[0102] Sensing all of these criteria and having redundancy built in
helps to avoid false triggers. Unique thresholds are set by the
control box 20 or the wireless misting controller 705 for each of
the three stimuli. Because the control box 20 and the wireless
misting controller 705 can be mounted anywhere on the unit housing,
the control box 20 and the wireless misting controller 705 sense
the conditions that are present during operation, and then
appropriately sets these thresholds for future determination of
whether the AC system is active.
[0103] 2. What the current air temperature/humidity environment is
surrounding the AC unit. Through testing, it has been determined a
good rule of thumb is that the minimum temperature threshold for
mist operation is about 75 degrees F. This minimum threshold is
flexible, depending on the relative humidity at any given time.
[0104] 3. How efficient that particular AC system is. Some AC
systems are old and inefficient and some are brand new and
efficient. To optimally determine when the control box 20 or the
wireless misting controller 705 should run, the control box 20 or
the wireless misting controller 705 performs periodic testing to
determine how well the AC system is cooling the home without the
aid of the control box 20 or the wireless misting controller 705.
Then, it compares operation with misting present to determine how
much the control box 20 or the wireless misting controller 705 is
increasing efficiency . . . if at all. These tests are done until
each temperature/humidity situation has been accounted for.
Temperature/Humidity Situational Analysis
[0105] If the assumption is made that evaporative pre-cooling
should not take place when temperature is below 75 degrees F., then
it is useful to analyze each degree above 75 degrees F. to
determine if misting should occur. Setting aside the factor of AC
system efficiency for a moment, the only other variable of
importance other than temperature when determining optimal misting
patterns is humidity. Since evaporative cooling is the method the
control box 20 or the wireless misting controller 705 uses to cool
the intake air, it follows that evaporation (and thus evaporative
pre-cooling) with more easily occur when the relative humidity is
low. However, even though complete evaporation of the water is
optimal, there is still benefit during the misting process when
unevaporated water hits the hot condenser fins. This also
facilitates increased efficiency, though not to the same extent as
the fine mist evaporating in the air. Thus, there are situations
where misting could be the correct financial decision even when the
humidity level is very high, if the temperature is sufficiently
high as well.
[0106] The algorithm will be continually adapted as more and more
qualitative testing data is accumulated from control boxes 20 or
the wireless misting controllers 705 all over the world. The
temperature scenarios will set up from 75 deg to 105 deg F, and the
humidity levels will be set up from 0% to 100% in 5% increments.
This implies a total of 651 temperature/humidity scenarios assuming
these preset ranges and 5% humidity increment rounding. It will be
understood that additional scenarios are also possible.
[0107] While it would take many, many tests at each individual
control box 20 or wireless misting controller 705 to determine
optimal operation by gathering data at each of the 651
temperature/humidity scenario combinations, by gathering the data
across all units that are installed worldwide it will be possible
to obtain data at each scenario rather quickly. Then, this
"crowdsourcing" of data can be harnessed to update onboard
thresholds for misting optimization for all customers. Current
humidity and temperature information for each location is pulled
from weather application program interfaces (API), and is then
combined with the temperature reading by the control box 20 or the
wireless misting controller 705 at the location. It will be
understood that a humidity sensor could be added to the control box
20 or the wireless misting controller 705.
AC Unit Efficiency Analysis
[0108] The other variable that is accounted for is the efficiency
of the AC system. By tracking the run-time length of a cycle, the
control box 20 or the wireless misting controller 705 can determine
how much workload is needed to cool the home without the control
box 20 or the wireless misting controller 705. Then, during another
cycle at the same temperature/humidity combination, the control box
20 or the wireless misting controller 705 can measure how much more
efficient the system is when mist is operating. These operation
metrics of the AC system can be compared to many other AC systems
to determine a relative efficiency value compared to other, known
systems. By categorizing AC systems together in groups as a
function of their efficiency in certain temperature/humidity
situations, data from testing can be applied more rapidly. For
example, each AC system can be given a rating on a 1-10 scale to
indicate how efficiently it runs. Then, this factor can be added to
the decision making process.
Make/Model Information Inputs
[0109] Customers are asked to provide the make, model, and size
(British Thermal Units (BTUs) or tonnage) of their AC unit when
they create an account. By collecting this information, the cloud
based servers (discussed below in connection with FIGS. 9, 10, and
12) will be able to immediately apply any data from other customers
with the same model unit. This will reduce the need for as testing
a specific AC unit to determine efficiency.
Power and Water Cost Inputs
[0110] Because there can be large discrepancies in prices customers
pay for water consumption and power usage, these variables must be
taken into account when deciding how to perfectly optimize misting
operation for each individual customer. Customers enter their price
in dollars per kilowatt-hour ($/kwh) for power as well as their
price in dollars/gallon for water. Other units for power and water
can be used as well in other countries as needed. Some areas also
have variable pricing depending on factors like total monthly
consumption or peak demand usage. These variables can dramatically
alter the cost benefit landscape and are be accounted for.
Customers will be able to enter in the peak hours that their power
supplier charges more for power, and the control box 20 or the
wireless misting controller 705 will take that information into
account when determining whether mist should be applied for given
AC cycles.
Decision Making Flow on Misting Operation. Must have "YES" Answer
for all to Mist:
[0111] In one or more embodiments, all of the following questions
must be answered in the affirmative in order to enable misting
(note that not all of these conditions need to be met in other
embodiments): [0112] Is enough EMF detected to determine AC unit
may be running? [0113] Is enough acoustic stimuli present to
determine AC unit may be running? [0114] Is enough vibration sensed
to determine AC unit may be running? [0115] Is temperature high
enough to warrant checking temp/humidity conditions table? [0116]
Is temp/humidity combination an acceptable condition for misting to
occur in an average situation based on information aggregated from
crowd sourced data? [0117] Does AC unit efficiency (from testing or
from make/model info) dictate that misting would be profitable at
this temp/humidity?
Cost Saving Potential Analysis of Each Situation:
[0118] Power is saved in two ways with the control box 20 or the
wireless misting controller 705. First, the control box 20 or the
wireless misting controller 705 allows the AC unit to cool the home
faster, meaning the AC unit runs less. Power savings are realized
through simply less power consumed to run the AC unit. Second,
because of the increased efficiency of the AC unit, it actually
uses less power while it's running as well. So savings for any
period of time can be quantified with the equation:
SAVINGS=[Power$current].times.[(RedRT).times.(KWH/secN)+(TotRT).times.(K-
WH/secN-KWH/secR)]-(RedRT.times.FlowR.times.Water$)
[0119] Where:
[0120] T/H=current temperature/humidity combination conditions,
[0121] FlowR=flow rate of water when the control box 20 or the
wireless misting controller 705 is running in gallons/sec
[0122] Water$=water cost in $/gallon
[0123] Power$current=current power cost in $/KHW (could vary during
peak usage times)
[0124] RedRT=Reduced run time (in seconds) due to the control box
20 or the wireless misting controller 705 misting operation
[0125] KWH/secN=KWH consumed per second without the control box 20
or the wireless misting controller 705 for T/H
[0126] TotRT=Total unit run time (in seconds) where the control box
20 or the wireless misting controller 705 is operating
[0127] KWH/secR=KWH consumed per second with the control box 20 or
the wireless misting controller 705 for T/H
Conclusion
[0128] The control box 20 or the wireless misting controller 705
algorithm for optimizing misting operation inspects a number of
different variables and performs cost saving analysis on each
specific weather scenario based on a customer's water and power
pricing, and the efficiency of their AC system. This will allow the
control box 20 or the wireless misting controller 705 to fully
maximize potential savings for each customer on an individual
basis.
Cloud Based Server
[0129] In one or more embodiments, illustrated in FIG. 9, the
wireless misting controller 705 interfaces through, for example, a
wireless access point 905 with a cloud based server 910. While only
one cloud based server 910 is shown, it will be understood that a
plurality of such servers may be used and that they may be located
in a central location or they may be distributed geographically. In
one or more embodiments, the cloud based server 910 communicates
with a mobile device 915 (or a personal computer, tablet, or other
computing device), to receive commands and information from the
mobile device 915 and to provide status and reports to the mobile
device 915. The wireless misting controller 705 operates to improve
the efficiency of compressor 920.
[0130] In one or more embodiments, the communications among the
wireless misting controller 705, the wireless access point 905, the
cloud based server 910, and the mobile device 915 are by way of a
network 925. In one or more embodiments, the network 925 includes a
wide area network (WAN)(such as the Internet), a personal area
network (PAN), a local area network (LAN), a metropolitan area
network (MAN), a virtual private network (VPN), and/or a wired
network.
[0131] In one or more embodiments, illustrated in FIG. 10, the
cloud based server 910 communicates with a plurality of wireless
misting controllers 705 via the network 925. The dashed lines and
solid lines in FIG. 10 indicate the possibility of independent
communications. For example, the dashed lines and solid lines
between the wireless misting controllers 705 and the wireless
access point 905 do not merely refer to handshaking that typically
occurs in wireless networks, but indicates the transmission of
commands and/or data to and from cloud based server 910.
[0132] The cloud base server 910 may take data from one wireless
misting controller 705 and use that data to control operations in
another remote wireless misting controller 705, as described above.
The cloud base server 910 may analyze data from one wireless
misting controller 705, and as a result of the analysis, provide
another wireless misting controller 705 with updates to its
programming, thresholds, or other data. Having multiple wireless
misting controllers 705 communicate with the cloud based server 910
allows the cloud based server 910 to analyze, configure, monitor,
measure, activate and/or deactivate a wireless misting controller
705 remotely based on desired parameters.
[0133] In one or more embodiments, a customer (not shown) may
control the settings, configure the program, and/or install updates
to the wireless misting controller 705 via a mobile APP. The
customer may also remotely access a wireless misting controller 705
via a computer that has access to the network 925.
Evaporative Cooling Boxes
Problem:
[0134] To precool an AC condenser one must broadcast a water mist
around the condenser allowing the mist to interact with the air,
before being drawn into the condenser's heat exchanger, to
evaporate and effectively drop the temperature of the air going
through the condenser thusly increasing the cooling systems
efficiency. Drawbacks of this method include the amount of water
that must be consumed in the process as well as the impact that
said water has on its surroundings. Excessive contact with ground
water can cause metal parts to corrode as well as leave mineral
deposits on critical surfaces impeding their function.
Solution:
[0135] Self-contained and controlled evaporative cooling modules
allow air and water to interact within a specially designed,
controlled environment, minimizing water consumption and water
associated impact on nearby surfaces (scale, rust, etc).
Operation:
[0136] With the cooling box, the water to air evaporation is kept
inside a controlled environment, completely removed from the
condenser unit. The design is such that no water will be allowed to
leave the proximity of the box, doing away with all possible water
contact with the condenser. Due to the wick type element design,
very little water is used to achieve a desirable cooling result.
Wicks are wetted by the control box 20 or the wireless misting
controller via a valve when needed and are then allowed to dry via
evaporation. Their vertical orientation ensures gravity will aid in
water dispersion on the material.
Construction:
[0137] Cooling box modules 1105, illustrated in FIG. 11, consist of
a shallow, hollow, box type housing (or box) 1110, with cut outs on
the front and rear faces 1115, 1120 to allow a large amount of air
to pass through. Very small mesh (400 mesh size, .about.0.013''
opening) stainless steel screens (not shown so other features can
be seen) are spanned across these openings to prevent debris from
entering the box and large water droplets from leaving the
apparatus. Located in the middle of the box is a removable framed
wick element insert 1125 that houses the water feed channels, which
can be fed by one or more manifolds 50 or adjustable manifolds 605,
and the wick elements 1130. The wick elements 1130 are made of a
special super absorptive material, namely PVA fabric (poly vinyl
acetate), that is treated with a compound that promotes and induces
water evaporation from its surfaces (silica). The wick elements
1130 are aligned in vertical strips to maximize surface contact
with the incoming air and cause minimal parasitic drag to the
condenser system.
Implementation:
[0138] The boxes 1110 are placed around the condenser unit, secured
by a mounting flange 1140, so that when the condenser fan turns on,
it draws air from the outside through the boxes 1110 and then
through the condenser itself. Upon condenser turn on detection, the
control box 20 or the wireless misting controller 705 will qualify
it for precooling assist by determining that the condenser is
indeed running via on board sensors and using these sensors to
answer operational questions such as: Is it warm enough? What is
the relative humidity? How long should the wicks be actively wetted
based on this information? When will the wicks need to be rewetted?
Once the cycle is qualified by the controller a valve, such as
solenoid valve 25, opens that allows water to flow into the box
plumbing system through a water connection 1135 (or through one or
more manifolds 50 or adjustable manifolds 605) thereby wetting the
wick elements 1130. This water will flow for a predetermined amount
of time based on local relative humidity as well as local
temperature readings so that the optimal amount of water is used to
wet the elements. As the air, being pulled by the condenser fan,
travels through the box 1110, it passes the wetted wick elements
1130 that readily allow the water to evaporate from their surfaces,
thusly cooling the air as it passes through them.
[0139] In one or more embodiments, venturi air vanes 1208,
illustrated in FIG. 12, located behind the wick elements 1130,
create enough turbulence and pressure drop to aid evaporation and
large droplet flocculation. In one or more embodiments, the venturi
shapes are created by two parallel air foils 1210, 1215, shown in
FIG. 12, with a triangular profile and air gap in between. As the
air stream enters the initial part of the venturi 1220, it slows
down and pressure builds. As the airstream leaves the initial part
of the venturi 1120, it reaches a dilution zone 1225 where pressure
rapidly drops and air speed rapidly increases. These flow and
pressure gradients help water evaporate initially, followed by
latter particulate removal via flocculation. In one or more
embodiments, the venturi air vanes 1208 are strips without the
triangular shape. When the air leaves the box 1110 it is now cooler
and free of liquid water or debris.
[0140] The cooler air can now be drawn through the condenser's heat
exchanger fins to cool hot refrigerant and dramatically increase
the system's efficiency. In one or more embodiments, the cooling
box module 1105 does not include the venturi air vanes 1208.
Cloud based server with cooling box module:
[0141] In one or more embodiments, illustrated in FIG. 13, the
manifold 50 or adjustable manifold 605 shown in the arrangement of
FIG. 9 is replaced by a cooling box module 1105.
[0142] In one or more embodiments, illustrated in FIG. 14, the
manifolds 50 or adjustable manifolds 605 shown in the arrangement
of FIG. 10 are replaced by a cooling box modules 1105.
Additional metrics:
[0143] In one or more embodiments, the following metrics, in
addition to or in replacement of those described above, can be used
to determine whether to mist:
Thermostat wirelessly connected to control box
[0144] The control box 20 or the wireless misting controller 705
may determine whether to mist based on whether a thermostat
wirelessly informs the control box 20 or the wireless misting
controller 705 that the compressor is running.
Additional temperature metrics:
[0145] The control box 20 or the wireless misting controller 705
may determine not to mist if the temperature is below a settable
temperature threshold.
[0146] The control box 20 or the wireless misting controller 705
may determine not to mist if ambient temperature is above (or
below) a temperature threshold and the rate of change of
temperature is above (or below) a rate of temperature change
threshold.
[0147] The control box 20 or the wireless misting controller 705
may determine to mist if temperature is rising at a threshold rate
and the temperature is above a threshold.
[0148] The control box 20 or the wireless misting controller 705
may determine not to mist if the temperature is falling at a
threshold rate and the temperature is below a threshold.
Additional Acoustic Metric
[0149] A noise maker (such as a simple horn) is attached to the
grill above the compressor fan. The noise maker makes a noise when
the fan is on. The control box 20 or the wireless misting
controller 705 may determine to mist upon detection of the low
noise.
Additional EMF Metric:
[0150] The control box 20 or the wireless misting controller 705
may determine to mist if measured counter electromotive force
(CEMF) is above a threshold.
[0151] A current measuring device is coupled to the power feed for
the compressor. The control box 20 or the wireless misting
controller 705 may determine to mist if the current measured by the
current measuring device is above a threshold.
Optical Metrics:
[0152] A mirror is placed on one of the blades of the compressor
fan and a led/detector is placed outside the compressor. The
led/detector receives a flash every time the blade with the mirror
passes. The control box 20 or the wireless misting controller 705
may determine to mist when the frequency of pulses exceeds a
threshold.
[0153] Another optical metric relies on the difference in light
intensity seen by a light detector positioned to detect light
coming up through the top of the compressor. The control box 20 or
the wireless misting controller 705 may determine to mist based on
the contrast between the intensity of the light when the fan is on
and the intensity of the light when the fan is off.
[0154] Another optical metric relies on the difference in light
intensity seen by a light detector positioned to detect light
coming up through the top of the compressor. The control box 20 or
the wireless misting controller 705 may determine to mist based on
a count of flashes caused by the difference between the intensity
of the light when a fan blade is below the light detector and when
there is no fan blade below the light detector.
[0155] Another optical metric relies on the difference in color
seen by a light detector positioned to detect light coming up
through the top of the compressor. The control box 20 or the
wireless misting controller 705 may determine to mist based on the
contrast between the color of the light when the fan is on and the
color of the light when the fan is off.
[0156] Another optical metric passes a light from one side of the
fan to the other (the light should enters and leaves the area above
the fan at an angle to that when the air is compressed there is
refraction causing the amount of received light to diminish) and
detect the change in the received light caused by diffraction
resulting from the compressed air from the fan
[0157] Another optical metric detects vibration in the compressor
by detecting a difference in flight time from a light source to a
surface on the compressor to a light detector.
Mechanical Metrics:
[0158] A generator (such as a fan) is placed at the top of the
compressor. Movement of the air through the generator will generate
electricity which can be detected. The control box 20 or the
wireless misting controller 705 may determine to mist when the
amplitude of the generated electricity reaches a threshold.
[0159] The compressor fan will move up or down slightly because of
the lift caused by the fan blades when it turns on or off. The
control box 20 or the wireless misting controller 705 may determine
to mist upon detecting (using, for example, flight time
measurements to and from an acoustic detector or a microwave
detector, or the like, to the fan) the slight movement as an
indication that the fan is on.
[0160] The inertia of the compressor will cause it twist on its
base to counter the rotation of the compressor shaft when it first
turns on. The control box 20 or the wireless misting controller 705
may determine to mist upon detecting the twist through a mechanical
sensor on the compressor mount or through an optical sensor that
can detect the motion of the compressor.
Combination:
[0161] The control box 20 or the wireless misting controller 705
may determine to mist based a combination of the metrics described
above, where the metrics or the metric thresholds are chosen based
on the values of some of the metrics; e.g., for low temperatures
use one set of metrics and for high temperatures use another set of
metrics.
[0162] It will be apparent to one of skill in the art that
described herein is a novel apparatus and method for increasing the
efficiency of an air conditioning unit. While the invention has
been described with references to specific preferred and exemplary
embodiments, it is not limited to these embodiments. The invention
may be modified or varied in many ways and such modifications and
variations as would be obvious to one of skill in the art are
within the scope and spirit of the invention and are included
within the scope of the following claims.
* * * * *