HVAC systems and related methods

Abstract

A method for controlling an HVAC system (10) includes at least one flow regulator (16), an electromechanical actuator (20), one or more sensors (34) associated with the actuator, and a controller (32) operatively connected to the actuator and the sensors. The method includes the steps of actuating the flow regulator, receiving signals from the sensors, and determining, based on the signals, whether an actual or impending fault exists. The determination is made whether the fault is in the actuator or in the flow regulator.

Description

Technical Field

[0001] This disclosure relates to the field of HVAC (heating, ventilation, and air conditioning) systems, and more particularly to the diagnostic operation of electronically controlled flow regulators within HVAC systems. Background Technology

[0002] HVAC systems installed in buildings or other facilities are expected to achieve high standards of safety and reliability. HVAC systems also contribute to building fire safety. Monitoring and testing of the system are crucial for maintaining reliability and safety standards. Legal requirements often mandate regular inspections of system performance.

[0003] Monitoring and testing HVAC systems involves the functionality of electronically controlled flow regulators (such as valves and dampers) that regulate the flow of fluids (gases and / or liquids, such as air and / or water). The efficiency and safety of the system can depend on the proper functioning of these regulators. Fire-resistant dampers are examples of electronically controlled regulators used to close air passages in an HVAC system in the event of a fire to prevent the spread of fire and smoke through the HVAC system within the building. Smoke-control dampers are similar examples of electronically controlled regulators designed to open to allow the extraction of smoke and fumes through ventilation ducts. Testing verifies that such dampers function correctly, close tightly, and open fully as required. Other electronically controlled regulators are also important for everyday ventilation, heating, and air conditioning.

[0004] Diagnosing the cause of an HVAC flow regulator failure is complex, especially when the regulator is assembled from multiple interacting operating components or units, such as flow control components, electromechanical components, and operating sensors in the fluid path. Because the different components of the regulator are often handled by different experts or require different levels of expertise, corrective action can only be taken after the fault has been correctly located. This problem is often exacerbated if electronically controlled flow regulators are located in areas where physical access is difficult; this situation is not uncommon.

[0005] If inspections are infrequent (e.g., every 6 or 12 months), faults may go undetected for extended periods, creating safety hazards. Besides addressing faulty regulators, another technical challenge involves identifying electronic control regulators at risk of future failures. Diagnosing potential future faults and their underlying causes, especially in regulators composed of multiple components, further increases the technical complexity.

[0006] Solving and / or mitigating one or more of the above problems would be desirable. Summary of the Invention

[0007] All aspects of this disclosure are embodied in the claims.

[0008] A first aspect of the present invention provides a method for controlling an HVAC system, comprising:

[0009] - At least one flow regulator, including an actuable element for regulating the flow rate of fluid in a fluid path;

[0010] - An electromechanical actuator associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor that drives a movable output member;

[0011] - One or more sensors associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors;

[0012] - A controller that can be operatively connected to actuators and sensors;

[0013] The method includes the following steps:

[0014] i. Actuated flow regulator;

[0015] ii. Receive signals from the one or more sensors;

[0016] iii. Based on the signals received in step ii, determine the actual or impending fault;

[0017] iv. Inform the operator of the HVAC system of the actual or impending failure;

[0018] The feature is that, in step iv, the following actual or impending faults are distinguished:

[0019] -Actuator; and

[0020] - Flow regulator.

[0021] This approach allows the controller to self-diagnose faults (actual or impending). By differentiating between actuator and flow regulator faults, the task of corrective action to repair or mitigate the fault becomes easier. Depending on whether the fault is caused by the flow regulator or the actuator, the appropriate expert (e.g., personnel and / or machine and / or robot) can repair, replace, or perform other maintenance on the appropriate unit, and / or document the fault in the appropriate technical documentation.

[0022] This is especially useful when flow regulators and actuators operate as integrated units but originate from different manufacturers, such as in OEM (Original Equipment Manufacturer) production processes, but it is not their only function. Flow regulators and actuators may be handled by different experts after manufacturing or require different expert skills.

[0023] The ability to self-diagnose actual and impending faults can significantly improve the safety (e.g., fire safety) of buildings where HVAC systems are installed. The performance of actuators and flow regulators can be monitored frequently as needed, for example, in some embodiments alongside normal operation. Furthermore, impending faults can be diagnosed and rectified in advance. Impending faults can be predicted, for example, corresponding to an increased risk or likelihood of failure even if the actuators and / or flow regulators remain operational at the time of diagnosis. Detecting impending faults is crucial for enabling predictive maintenance applicable to individual actuators and / or flow regulators and can supplement or utilize, not just, scheduled maintenance programs.

[0024] Another advantage of self-diagnostics is that it can provide operators with crucial information about whether the HVAC system is correctly set up and / or sized. For example, this information can enable operators to optimize the HVAC system for a better cost structure and / or desired reliability.

[0025] As used herein, the term flow regulator can refer to any device used to regulate fluid flow in a flow path by adjusting an orifice, such as a damper, flap, or valve. A flow regulator can be of the type having two discrete states, such as open and closed; or a flow regulator can be of the type having three or more discrete states, such as open, closed, and one or more intermediate states; or a flow regulator can be of the type defining a continuously variable orifice size, such as continuously variable between fully open and fully closed. The actuating part of a flow regulator can be, for example, any movable element, such as a damper blade, valve ball, valve plug, valve flap, etc.

[0026] In some embodiments, the lever mechanism can operatively connect the output component of the actuator and the flow regulator. Other types of mechanisms, or direct or indirect coupling between the actuator and the flow regulator, may be used alternatively as needed.

[0027] In some embodiments, the actual or impending failure of the flow regulator is selected from the group consisting of: worn bearings; improperly secured bearings; worn washers; deformed damper sleeves; damaged damper blades; blockage of the actuating parts of the flow regulator, for example caused by foreign objects or by excessive dirt or contamination of the medium in the fluid path.

[0028] Alternatively or concurrently, in some embodiments, the actual or impending failure of the actuator is selected from the group consisting of: a defective or worn bearing for the output component; a defective or worn output gear; a defective actuator mount; a defective motor; a defective motor bearing; a defective connection to the flow regulator; a non-attached connection to the flow regulator; a defective return spring; a defective supercapacitor supplying power to the actuation at a predetermined position in the event of a power failure; a defective battery supplying power to the actuation at a predetermined position in the event of a power failure; and defective electronic circuitry.

[0029] For example, a non-attached connection state relative to the flow regulator may occur if the actuator and flow regulator are not properly assembled during manufacturing or installation. As discussed later, detecting such faults can be important when the flow regulator and actuator are integrated into an HVAC system. A non-attached connection state can be diagnosed by defining a predetermined travel range for the flow regulator and monitoring whether the flow regulator in use achieves its travel range and / or whether the actuator measures movement beyond its travel range. The travel range can be sensed, for example, by one or more position sensors or end-stop sensors, or by monitoring other parameters, such as load or current, when the flow regulator is actuated to reach the end-stop position. In one example, the flow regulator may be mechanically limited (e.g., by an end-stop element) to a travel range of 0° to 90°. If the actuator measures an angle beyond the limit from its output element (e.g., less than 0° or greater than 90°), this may indicate that the actuator's output element is not operatively attached to the flow regulator. The travel range of the flow regulator can also be determined indirectly, for example, by: (i) determining the angular distance the motor has traveled (e.g., by a position sensor or by sensorless derivation of the motor controller); and (ii) calculating the corresponding travel range of the flow regulator using a known gear ratio.

[0030] In addition to the sensors associated with the actuator, in some embodiments, the HVAC system also includes one or more sensors selected from the group consisting of: temperature sensors; humidity sensors; flow sensors; wind speed sensors; air / fluid quality / contamination sensors; viscosity sensors; concentration sensors; and optical sensors (e.g., CCD sensors or cameras). For example, optical sensors may monitor the operating status and / or condition of the flow regulator, and / or may monitor dirt and / or contamination of the medium in the flow path.

[0031] Such sensors can provide the controller with additional information related to time parameters that may affect the operating characteristics of flow regulators and / or actuators. For example, temperature and / or pressure and / or fluid contamination can affect how the regulator operates. Providing the controller with this information can help it compensate for such parameter changes when an actual or impending fault is detected.

[0032] Alternatively or in some embodiments, in step iii, while determining the actual or impending fault, the following are considered as corrective compensation:

[0033] - The flow rate of the medium through the flow regulator; or

[0034] - The temperature of the actuator during operation, preferably the temperature of the actuator motor; or

[0035] - Temperature of the fluid in the flow path of the flow regulator or

[0036] - Historical records of actuator torque and / or actuator temperature;

[0037] and their combinations.

[0038] Alternatively or additionally, in some embodiments, historical information may be recorded to determine the service life of the flow regulator and / or actuator. For example, in some embodiments, the number of cycles and / or the count of direction changes of the flow regulator and / or the total operating time and / or the total stroke; and / or the number of cycles and / or the count of direction changes of the actuator and / or the total operating time and / or the total stroke are recorded.

[0039] A variety of techniques can be used to identify and distinguish between actual and impending failures.

[0040] In some embodiments, in step iii,

[0041] - The actuator itself has a reference torque or current profile without a flow regulator; and / or

[0042] - A reference curve associated with the flow regulator itself without an actuator; and / or

[0043] - Reference torque or current curve when the actuator and flow regulator are operably connected;

[0044] Used to identify actual or impending failures.

[0045] Using a reference torque or current profile of the actuator itself (without a flow regulator) can provide the controller with useful baseline information about the actuator's characteristics, unaffected by the flow regulator. This can help identify and differentiate between actuator-related faults (actual and / or impending).

[0046] Similarly, using a reference curve associated with the flow regulator itself (without an actuator) can provide the controller with useful baseline information about the characteristics of the flow regulator alone, unaffected by any actuator. This can help identify and differentiate between actual and / or impending faults associated with the flow regulator.

[0047] Similarly, when operatively connected to a flow regulator, the actuator's reference torque or current profile provides baseline information on how the two units perform together, which is typically the operating condition that will be evaluated by this method.

[0048] Alternatively or concurrently, in some embodiments, in step ii...

[0049] - Torque and / or current curves when the flow regulator is actuated or released; and / or

[0050] - The position of the output component over time when the flow regulator is actuated or released; and / or

[0051] - The integral calculated based on the torque curve and / or current curve when the flow regulator is actuated or released; and / or

[0052] - The position of the output component at the maximum torque amplitude and / or the maximum current amplitude and / or the maximum amplitude of the calculated torque derivative and / or the maximum amplitude of the calculated current derivative; and / or

[0053] - The position of the output component in the open and / or closed position of the flow regulator; and / or

[0054] - The position of the output component at the end of the flow regulator's stroke range; and / or

[0055] - The derivative or torque and / or current when the flow actuator approaches the open and / or closed position; and / or

[0056] - Variations in torque and / or current within the predetermined operating range; and / or

[0057] - The speed at which the actuator and / or the flow regulator moves when the flow regulator is actuated; and / or

[0058] - The return time of the return mechanism when operating in the self-return valve;

[0059] It was recorded.

[0060] The released actuator mentioned above refers to an actuator configured to move an output member to a predetermined operating position in response to a power outage. The predetermined position may, for example, correspond to the open position, closed position, or some intermediate position of a flow regulator. Upon power failure, the actuator is released, and the output member is driven to the predetermined position. For example, the actuator may include a spring (e.g., a return spring) to drive the movement, or the actuator may include a backup power source, such as a supercapacitor or battery, to provide backup power for actuation.

[0061] The derivative mentioned above refers to the mathematical derivative function (e.g., differential) that performs the indication of rate of change. The integral mentioned above refers to the mathematical integral function that performs the indication of accumulation or aggregation. The maximum value of the parameter or calculation mentioned in this article can generally refer to the maximum magnitude where the directionality of the actuator and / or flow regulator's motion may be negative due to the orientation reference frame.

[0062] For example, the movement speed of an actuator and / or flow regulator during actuation can provide insight into whether the actuator is overloaded. The actuator can be pre-programmed or expected to operate at a specific speed window, such as a motor rotating at approximately 2500 RPM. If the actuator deviates from the expected speed by more than a set value, it may indicate a malfunction, such as actuator overload due to some cause. Speed ​​detection can provide additional or alternative performance information compared to torque / current information. For example, speed can be detected or correlated with the voltage across the motor, or speed can be measured by detecting changes in the actuator position relative to time, for example, by calculating the rate of pulses generated from a rotation sensor, or by the mathematical derivative of a position-related signal.

[0063] For example, detecting the position of the output component at the end of the flow regulator's range of motion can be used to detect a non-attached connection between the actuator and the flow regulator, as described above. It can also be used to detect abnormal blockages or other obstructions in the actual range of motion of the flow regulator in use. The position where the flow regulator stops at the expected open or closed position can be used to detect whether the range of motion is obstructed compared to the expected range of motion, for example, if the flow path is blocked by a foreign object.

[0064] Alternatively or concurrently, in some embodiments, in step iv, the hysteresis of the actuator and / or lever mechanism (if present) is used to distinguish between actuator and flow regulator failures. Hysteresis can provide a useful distinguishing tool because it is primarily a characteristic of components other than the flow regulator (i.e., the actuator and / or lever mechanism (if present)). If desired, the actuator and / or lever mechanism can even be designed with amplified hysteresis to provide a larger window for detecting component-related failure parameters other than the flow regulator.

[0065] The controller may optionally be a local and / or uniquely associated device with the respective actuator. For example, the controller may have the actuator mounted on it, and / or be integrated with the actuator, and / or be contained within the same housing as the actuator. Such a local controller may optionally communicate operational data with a system controller or group controller that controls multiple flow regulators.

[0066] Alternatively, the controller mentioned above may be a controller operatively connected to and / or operatively communicating with the respective actuators of the multiple flow regulators for controlling the multiple flow regulators according to the method described herein.

[0067] The closely related second aspect provides a method for setting up an HVAC system, optionally operated according to any of the method steps of the first aspect, wherein the HVAC system includes:

[0068] - At least one flow regulator, including an actuable element for regulating the flow rate of fluid in a fluid path;

[0069] - An electromechanical actuator associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor that drives a movable output member;

[0070] - One or more sensors associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors;

[0071] - A controller that can be operatively connected to actuators and sensors;

[0072] The method includes the following steps:

[0073] i. Actuating flow regulator; and / or

[0074] ii. The actuator itself is actuated, but the output component is not operatively connected to the flow regulator;

[0075] iii. Receive signals from the one or more sensors during steps i and / or ii;

[0076] iv. Based on the signals received in step iii, determine the actual or impending fault;

[0077] v. To indicate the actual or impending failure;

[0078] The feature is that, in step v, the following actual or impending faults are distinguished:

[0079] -Actuator; and

[0080] - Flow regulator.

[0081] Optionally, the method further includes the steps of

[0082] - Based on the signals received in step iii, provide the user with guidance on how to overcome the fault.

[0083] In any of the foregoing aspects, the method may explicitly include diagnosing an impending failure, and / or distinguishing between an impending failure and an actual failure in the determination and / or indication steps.

[0084] In some embodiments, the step of determining an actual or impending fault may include diagnosing an impending fault. Alternatively or additionally, the step of determining an actual or impending fault may include diagnosing an actual fault. Alternatively or additionally, the step of determining an actual or impending fault may include diagnosing both actual and impending faults (e.g., diagnosing both actual and impending faults).

[0085] In some embodiments, the step of determining an actual or impending fault includes:

[0086] - Determine whether the signals received from the one or more sensors correspond to an impending fault; and

[0087] - Determine whether the signals received from the one or more sensors correspond to an actual fault.

[0088] Alternatively or alternatively, the steps for indicating an actual or impending failure may include distinguishing between an actual failure and an impending failure.

[0089] A closely related third aspect of this disclosure may relate to providing an HVAC flow regulator actuator as a unit, which is useful for manufacturers to incorporate into or with an HVAC fluid flow regulator, and optionally provides functionality for any of the above methods.

[0090] Therefore, a third aspect of this disclosure provides a method comprising:

[0091] - Obtain an actuator unit, which includes:

[0092] - Electromechanical actuators, including electric motors for driving movable output components, for transmission

[0093] The mechanical motion of the actuator is delivered;

[0094] - One or more sensors associated with the electromechanical actuator, wherein the sensors are selected from load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, etc.

[0095] A group consisting of sensors, speed sensors, and position sensors; and

[0096] - A controller that can be operatively connected to electromechanical actuators and sensors.

[0097] - Assemble the actuator into the flow regulator, which includes an actuable element for regulating fluid flow in the fluid path in response to movement of the actuator output member; and

[0098] - The operation controller registers and / or records information about the operating characteristics of the flow regulator after assembly, optionally before and / or after installation in the HVAC system, based on signals from at least one of one or more sensors.

[0099] Using this method, the controller can register information necessary for the controller to subsequently determine an actual or impending fault. Optionally, this information can help distinguish between faults (actual or impending) in the actuator unit and the flow regulator.

[0100] The method may further include operating the controller to register and / or record information about the operating characteristics of the actuators and flow regulators before and / or after installation into the HVAC system, based at least on signals from at least one of one or more sensors. This further step, if used, can replace and / or update the information about the operating characteristics of the actuators and flow regulators to reflect changes that occur on-site once in the HVAC system.

[0101] Preferably, the method may further include:

[0102] -Actuation flow regulator;

[0103] - Receive signals from the one or more sensors;

[0104] - Determine the actual or impending fault based on signals received from sensors and information obtained directly or indirectly from the preceding registration steps.

[0105] The steps involved include distinguishing between actual or impending failures in the actuator and flow regulator.

[0106] Although certain features have been highlighted in the foregoing and appended claims, any novel features or ideas described herein and / or shown in the accompanying drawings are protected, whether highlighted or not. Attached Figure Description

[0107] Figure 1This is a schematic block diagram showing the function blocks of the electrically controlled flow regulator in the HVAC system.

[0108] Figure 2 yes Figure 1 A schematic diagram of the torque curve of the flow control device used.

[0109] Figure 3 It is similar to Figure 2 A more detailed schematic diagram of the torque curve.

[0110] Figure 4 This is a schematic diagram showing the effect of sealing behavior on the torque curve.

[0111] Figure 5 This is a schematic diagram illustrating the first example of how wear on a flow regulator affects a torque curve.

[0112] Figure 6 This is a second example of a schematic diagram showing the effect of flow regulator wear on the torque curve, specifically where the damper bearing becomes defective.

[0113] Figure 7 It is a schematic diagram showing how different behaviors of the flow regulator when it reaches the open position affect the torque curve.

[0114] Figure 8 This is a schematic diagram showing the effect of actuator wear on the torque curve.

[0115] Figure 9 This is a schematic diagram illustrating the effect of actuator break-in on the torque curve.

[0116] Figure 10 It is a schematic flowchart showing the information processing steps and modules used to detect faults based on data models and inputs received from sensors.

[0117] Figure 11 It is a diagram that displays key performance information and shows how to use this information in the diagnostic module to detect faults.

[0118] Figure 12 This is a schematic diagram showing the first set of parameters in the first example of a flow control device test.

[0119] Figure 13 It is a display Figure 12 A schematic diagram of the second set of parameters in the first example.

[0120] Figure 14 Is it for display use Figure 11 The graph, based on Figure 12 and 13 A schematic diagram illustrating the diagnosis of parameters.

[0121] Figure 15This is a schematic diagram showing the first set of parameters in the second example of a flow control device test.

[0122] Figure 16 It is a display Figure 15 A schematic diagram of the second set of parameters in the second example.

[0123] Figure 17 Is it for display use Figure 11 The graph, based on Figure 15 and 16 A schematic diagram illustrating the diagnosis of parameters.

[0124] Figure 18 It is similar to Figure 10 The schematic flowchart is enhanced to adapt to information that changes over time.

[0125] Figure 19 This is a schematic diagram showing the effect of temperature on the torque curve.

[0126] Figure 20 This is a schematic diagram showing the effect of fluid pressure on the torque curve.

[0127] Figure 21 It is similar to Figure 18 The schematic flowchart shows further enhancements with adaptive analysis.

[0128] Figure 22 It is shown in Figure 21 A schematic block diagram of the processing modules used in the flowchart.

[0129] Figure 23a and 23b These are the upper and lower halves of a schematic flowchart, illustrating the steps from manufacturing to commissioning and testing of the flow control device. Detailed Implementation

[0130] Non-limiting embodiments of this disclosure will now be described by way of example only with reference to the accompanying drawings. The same reference numerals are used to denote corresponding features, whether or not they are described in detail.

[0131] refer to Figure 1 At least one electronically controlled flow control device 12 is shown as part of the HVAC system 10 for controlling fluid flow within the fluid path of the HVAC system. To avoid diagrammatic confusion, Figure 1 The fluid paths or other details of the HVAC system 10 are not shown; only features relevant to understanding this disclosure are depicted. Preferably, a plurality of devices 12 are provided. The fluid may be a liquid and / or a gas. Exemplary liquids may include water and / or glycerol. Exemplary gases include air.

[0132] In some embodiments, device 12 may be a fireproof damper or be shown in the form of a fireproof damper. As described above, a fireproof damper is a safety device installed in an HVAC ventilation duct. In the event of a fire, the fireproof damper closes to seal the passage and prevent the spread of fire and smoke through the HVAC system. However, the reference to fireproof dampers herein is merely illustrative and should be understood to extend to other types of fluid control devices 12, such as, but not limited to, smoke control dampers.

[0133] Each device 12 typically includes a flow regulator 16. The flow regulator 16 can be any device for regulating the flow of fluid through an orifice, such as a damper, flap, valve, etc. The flow regulator 16 includes an actuable element 18 in the fluid path, for example, in the form of a multi-bladed damper, valve ball, valve plug, valve disc, etc.

[0134] Each device 12 may also include an electromechanical actuator 20 associated with the flow regulator 16 for actuating the physical movement of the regulator 16. The actuator 20 may include an electric motor 22 or drive a movable output member 24 (in... Figure 1 Other main drives (shown schematically only). Optionally, a transmission 26, such as a gear transmission, couples the rotor of motor 22 to output member 24. In one example, output member 24 includes a rotating member that can move about an axis through a range of approximately 90°.

[0135] The output member 24 is directly or indirectly coupled to the actuable element 18 of the flow regulator 16. In some embodiments, a lever mechanism 28 operably links the output member 24 to the actuable element 18, but other types of mechanisms, or direct or indirect couplings, may be used alternatively as needed.

[0136] Actuator 20 may also optionally include a self-positioning device 30 for setting or returning the output member 24, and thus the flow regulator 18, to a predetermined reference position when power is removed from actuator device 12. For example, the reference position may be a fully closed position or a fully open position. In some embodiments, device 30 may include a mechanical energy storage device, such as a spring, to push the output member 24 toward the reference position. In other embodiments, device 30 may include an electrical energy storage device, such as a battery or supercapacitor, for providing stored power to actuator 20 for automatic movement to the predetermined reference position.

[0137] The actuator 20 also includes a controller 32 for driving the motor 22 to achieve the commanded movement of the regulator. The controller 32 also receives signals from one or more sensors 34 associated with the actuator 20 (optionally associated with the motor 22). The sensing parameters at the motor 22 can be technically more easily implemented. The sensors 34 may include one or more selected from the group consisting of load sensors, force sensors, torque sensors, current sensors (I), voltage sensors (V), power sensors, speed sensors, position sensors (Pos), and temperature sensors (°T).

[0138] Sensor 34 can be a physical sensor for directly sensing parameters and / or a virtual sensor for deriving the value of the sensed parameter from other measurements. For example, a position sensor can derive the calculated position from a set of position increments sensed by an incremental sensor. The position of the output member 24 can also be calculated from the equivalent position of the motor rotor shaft by taking into account the hysteresis or backlash in the transmission 26. For example, hysteresis can be a position rotation of approximately 5°. The operating range of 0-95° determined at the rotor shaft corresponds to the actual movement of the output member 24 within the range of 0-90°. The initial 5° of rotor movement is lost in the hysteresis. Therefore, the remaining range of 5-95° determined at the rotor shaft corresponds to the 0-90° movement of the movable member 24.

[0139] According to motor 22, such as a vector control motor, position and / or torque measurements can also be derived from signals sensed by spatial permeability fluctuations in motor 22. This technique is described, for example, in WO-A-99 / 39430.

[0140] The controller 32 may also receive signals from one or more external sensors 36. The external sensors 36 may be associated, for example, with the flow regulator 18, or with different components of the HVAC system, or with the building or other installations implementing the HVAC system. The external sensors 36 may, for example, sense fluid flow rate, fluid velocity, fluid pressure, and / or temperature in the fluid path, and / or the degree of dirt or contamination in the fluid path, and / or the actual operating position of the actuable element 18.

[0141] Sensors 34 (and 36) can be one or more different types, including, for example, optical sensors, acoustic sensors and magnetic sensors.

[0142] The flow control device 12 responds to commands from the system controller 38, which communicates with the system controller 38 via a communication channel, which may be wired and / or optical and / or wireless.

[0143] Figure 1The diagram also shows a remote data processing system 40, which can optionally communicate operatively with actuator controller 32 and / or HVAC system controller 38 via a portable device 42 (described later) or via one or more communication channels independent of portable device 42. For example, communication can be via an Internet address and / or Internet communication protocol, or other networks, or direct communication. Remote data processing system 40 can be a so-called cloud system or service. The connection can be permanent or occasional, such as on-demand connection. The connection can be wired and / or optical and / or wireless.

[0144] This embodiment is characterized by its ability to automatically diagnose faults in device 12 based on signals sensed by sensor 34 (and optionally 36), whether the fault is an actual or impending fault. Diagnosis may also include distinguishing whether the fault (actual or impending) is in actuator 20 or flow regulator 16. This facilitates the task of repairing or mitigating fault correction actions. Depending on whether the fault is caused by the flow regulator or the actuator, appropriate experts can repair, replace, or otherwise maintain the appropriate unit. Diagnosis of impending faults allows for timely inspection and maintenance to prevent actual fault occurrence. Diagnosis may be performed by actuator controller 32 and / or HVAC system controller 38 and / or remote processor 40.

[0145] Diagnostics are performed based on a data model 48 representing the performance of device 12 and / or the device. The data model 48 can be performed by first referencing performance curves ( Figure 2 To best understand this, the performance curve represents the change in characteristics during the cycle of opening and closing the flow regulator 16. The performance curve can be a load curve, such as a force curve or a torque curve. In the illustration, the performance curve is torque curve 50, but it should be understood that references to torque herein should be interpreted as applying equally to load and / or force characteristics. Torque can be measured or calculated, or it can be assumed that torque is proportional to the current flowing through motor 22. However, other performance curves (e.g., speed, voltage, power, etc.) can be used additionally or alternatively as needed. Furthermore, although the performance curve represents the operation of a fire damper, the same principle can be applied to other types of flow regulators. Figure 3 This highlights the availability from Figure 2 Certain characteristics are derived from the performance curves. At least one, preferably some, more preferably most, and optionally all of these characteristics may be useful to data model 48.

[0146] refer to Figure 2The technique disclosed herein is to divide the performance (e.g., torque) curve 50 into certain operating windows or regions. Each window represents an operating phase, in which associated parameters can track how the actuator 20 and flow regulator 16 operate and can reveal actual or impending failures.

[0147] The first window (or "lag" window) 52 is the time it takes for the motor 22 to begin rotating from the 0° rotational position. Mechanical backlash or lag in the transmission 26 may cause the motor rotor to rotate approximately 5° without significant movement of the output component 24. See also Figure 3 During this window, the torque is relatively low and can be referred to as the "minimum torque" generated by motor 22 during the cycle. The torque curve is primarily affected by the condition of actuator 20, i.e., by motor 22 and transmission 26. This window can be represented by one or more of the following: angular position information of the first window (e.g., one or more of start position, end position, and angular width); and / or torque information defining the torque during the window (e.g., maximum torque and / or average torque).

[0148] refer to Figure 2 and Figure 3 During the second window (“seal open” window) 54, the output member 24 begins to move, causing the flow regulator 16 to begin opening. The seal of the flow regulator 16 creates additional friction during this opening movement, and the torque rises to a local peak 56 before returning to a moderate level after the seal opens. An example of such a seal is a lip seal, which, when leaving the closed state, must be forced to flip itself, resulting in a noticeable peak 56. During this second window, the rotor can rotate from approximately 5° to approximately 20°. The local peak 56 is generated by the action of the seal and provides an indication of the sealing condition. For example, Figure 4 The effects of weakened or inoperable sealing are shown, which may reduce the height of local peak 56 and shift the angular position of peak 56. The second window may be represented by one or more of the following: angular position information of the second window (e.g., start position, end position, angular width, or one or more); and / or information about the peak properties (e.g., peak height, angular position of local maximum within the second window, mathematical integral of the peak curve, which provides an indication of the area under the peak).

[0149] During the third window (“progressive” window) 58, the torque change remains substantially uniform as the motor 20 drives the flow regulator progressively toward full opening. In this example, the actuator includes a spring (“return spring”) 30 to return the flow regulator to the closed position when power is cut off, and the torque increases moderately linearly as the motor operates to compress / extend the return spring 30. The motor rotor rotates from approximately 20° to approximately 85°. The third window 58 corresponds to the main range of motion of the actuator 20 and the flow regulator 16. The torque generally increases gradually and moderately throughout the window, and any dispersion of the torque (e.g., standard deviation) is most noticeable in this window, which may be an indicator of bearing condition. The third window can be represented by one or more of the following: angular position information of the third window (e.g., one or more of start position, end position, and angular width); and / or dispersion information (e.g., standard deviation of the mean); and / or curve shape information (e.g., maximum torque value and / or corresponding angular position). Dispersion can be evaluated by sampling, for example, approximately 100 data points within the window and calculating the standard deviation. The standard deviation can be a single value for the entire window 58, or a single value for a representative segment 58a of window 58, or window 58 can be subdivided into multiple segments, and the standard deviation can be calculated for each segment. For example... Figure 3 As shown, the expected torque is minimum at the beginning of the window and maximum at the end of the window. Figure 5 and 6 This illustrates how a faulty flow regulator 16 affects the torque in the second window. Figure 5 The diagram shows a worn valve bearing that cannot adequately support the forces applied by actuator 20. The sealing peak 56 may shift, and the torque curve in the third window is non-linear. Figure 6 The diagram shows the increased torque required by the worn valve towards the end of the stroke in the third window, which also results in non-linear torque characteristics.

[0150] refer to Figure 3 The actual torque at the end of the third window can also be recorded, regardless of whether it is the absolute maximum value. The difference between the initial torque at the beginning of the first window 52 and the final torque at the end of the third window 58 also represents the amount of energy stored in the return spring 30, and thus the condition of the spring 30. This value can be called the "rise feather".

[0151] Subsequently, during the fourth window (“Open Stop” window) 60, the flow regulator 16 reaches the fully open position and comes to a hard stop. As the motor 20 stalls, the torque increases abruptly with an almost step-like pulse characteristic. This operational phase corresponds to the rotor rotating from approximately 85° to approximately 95°. The abruptness of the stop also indicates the condition of the coupler 28 of the flow regulator 16 and the actuator. If the actuator component 18 is blocked before fully opening, or if the coupler 28 becomes worn or weakened, the motion tends to slow down more gradually before coming to a complete stop. For example, the coupler 28 may deform slightly under stopping load. The torque curve will then have a less steep slope, especially at the beginning of the fourth window 60, for example, as shown below. Figure 7 As shown at point 68. The fourth window can be represented by one or more of the following: angular position information of the fourth window (e.g., start position, end position, angular width, or one or more); and / or slope information of the torque curve (e.g., mathematical derivatives and / or differential values ​​indicating the gradient).

[0152] The difference in angular position from the beginning of the first window 52 to the end of the fourth window 60 also provides an indication of the total stroke of the actuator 20 as it moves from closed to open.

[0153] The total duration from the start of the first window 52 to the end of the fourth window 60 provides additional important information about how fast the control device 12 operates.

[0154] The torque curve is also shown as including a fifth window (“return” window) 62, which corresponds to the spring 30 returning the drive member 24 and the flow actuator 16 to the fully closed position when the motor 20 is powered off. During the fifth window 62, the torque curve becomes negative as the spring drives the motor 20, thereby inducing current and voltage in the motor. The duration of the self-return provides an indication of the condition of the spring 30 and / or the degree of friction in the actuator 20 and the flow regulator 16. The voltage or current induced in the motor 20 during the return can also provide an indication of the uniformity of the return speed. The fifth window can be represented by one or more of the following: time information indicating the self-return time; voltage and / or current information indicating the characteristics of the return path.

[0155] Figure 3 It also indicates the maximum permissible torque threshold 64 set for the control device 12. Threshold 64 represents a safe limit that should not be exceeded during normal use of the control device 12, even though there is a momentary pulse from the trigger controller 32 to stop the actuator 20 at the point when the flow regulator 16 reaches its maximum opening. For example, Figure 8The diagram shows a faulty actuator 20 that, due to increased friction or bearing wear over time, requires greater torque to drive the flow regulator and eventually exceeds the maximum threshold 64 (at 70) after, for example, approximately 100,000 operating cycles.

[0156] Figure 3 The variation of torque curve 50 depending on when it is acquired is also shown. A preferred feature of this disclosure is the recording of performance information at different production and installation stages of the control device 12. Data model 48 may be based on and / or include the performance information recorded at these different stages.

[0157] For example, a first torque curve 50a, measured before the actuator 20 is mated or assembled with the flow regulator 16, is shown. This provides information associated with the actuator 20 itself, unaffected by the flow regulator 16. Figure 3 As can be seen, the first curve 50a has no local peak 56, and the information recorded from the first curve 50a provides a view of the pure actuator behavior even outside the hysteresis window 52.

[0158] A second torque curve 50b of the actuator after manufacturing and assembly with the flow regulator 16 is shown. Figure 3 As can be seen, compared to the first curve 50a, the second curve 50b includes a relatively significant local peak 56. The information recorded from the second curve 50b provides a view of the performance of the actuator 20 and the flow regulator 16 when they are new together.

[0159] The third torque curve 50c is shown for device 12 after its installation in the HVAC system and after a certain number of operating cycles that allow for component break-in. Figure 3 As can be seen, when new, the third curve 50c is typically lower than the second curve 50b. The break-in process reduces friction in the actuator 20 and flow regulator 16. Furthermore, when new, the grease within the transmission 30 may be relatively viscous or sticky. Break-in reduces the viscosity of the grease, which also helps reduce friction. Figure 9 It was also shown that at point 72, the torque decreased as the number of operating cycles increased during the break-in period of actuator 20.

[0160] refer to Figure 10 and 11 The information derived from the performance curve is called KPI (Key Performance Indicator). Figure 10 This is a schematic diagram illustrating the processing steps or modules used to analyze KPIs. Figure 11 This is a table showing how to interpret different KPI parameters to distinguish between the failures of actuator 20 (left column) and flow regulator 16 (right column).

[0161] refer to Figure 10 KPI 80 is obtained at three different stages 82 of manufacturing and installation discussed above: (i) for actuator 20 alone before assembly to flow regulator 16; (ii) for actuator 20 and flow regulator 16 together after assembly; and (iii) for control unit 12 once installed in the HVAC system, and optionally after a break-in period. Alternatively or additionally, the control unit's KPI can be obtained during, immediately after, or shortly thereafter during installation in the HVAC system so that any changes or effects of the installation on the control unit 12 can be considered compared to when it was new (e.g., even before break-in). Optionally, the characteristics of the control unit 12 can be measured immediately before installation. This allows effects such as deformation of the fluid flow path caused by piping to be taken into account.

[0162] KPI 80 forms at least a portion of data model 48. To diagnose current performance, the current values ​​of the KPI parameters are calculated based on signals provided by sensor 34 (and optionally 36) during partial or complete on-off cycles commanded by controller 32, either during dedicated test runs or normal operation of the HVAC system. Furthermore, KPIs from one or more previous runs are used as historical data, optionally in the form of a weighted average, to enable tracking of changes and / or trends in the KPIs. Previous KPIs and / or weighted averages may be stored as part of the evolving data model or as separate information.

[0163] refer to Figure 11 The KPIs in the data model may include one or more of the following (optionally at least some and / or at least most and / or all):

[0164] 84: First torque information (e.g., maximum torque) associated with the first window 52 (e.g., associated with actuator hysteresis).

[0165] 86: Second torque information (e.g., peak torque 56) associated with the second window 54 (e.g., associated with a seal).

[0166] 88: Third torque information (e.g., maximum torque) associated with the third window 58 (e.g., associated with the gradual opening of the flow regulator).

[0167] 90: Fourth torque information associated with the difference between the torque at the start of the first window and the end of the third window (e.g., associated with the energy stored in the spring 30).

[0168] 92: Fifth torque information (e.g., calculated standard deviation) associated with the distribution of torque during the third window.

[0169] 94: The sixth torque information associated with the calculated integral of peak 56 in the second window.

[0170] 96: Full range information associated with the operating range of the movement of the control device 12, for example, based on the angular range or difference between the start of the first window 52 and the end of the fourth window 60.

[0171] 98: The time formation associated with the duration of the fifth window 62 (e.g., the return time from opening to closing under the force of spring 30).

[0172] Optionally, the KPI may further include a seventh torque information (not shown) that is associated with the slope calculated at the beginning of the fourth window 62 (e.g., associated with an indication of how the flow regulator 16 stops in its open position).

[0173] refer to Figure 10 At point 102, the current KPI is compared with certain thresholds in the data model to see if it exceeds certain safety limits, namely:

[0174] (i) Whether the torque (or maximum torque) during one of the windows exceeds or approaches the maximum permissible torque threshold 64. In the current example, determining whether the torque exceeds the permissible threshold 64 by a specific fraction, such as 95%, is for the purpose of generating a warning. Such a high torque value indicates an increase in friction or other motion resistance and should be checked by inspection. A warning for excessive torque without other indicators may be associated with a malfunction of actuator 20.

[0175] (ii) Whether the total travel distance or angle (e.g., from closed to open) has changed significantly compared to historical total travel. For example, it can be determined whether the total travel has increased or decreased by more than a certain proportion compared to historical total travel information and / or compared to similar travel information from other flow control units 12 (which may be included in the data model and / or provided as external information). Any change in total travel, except for a modest change, may indicate a malfunction. A reduced travel may indicate that the flow regulator 16 cannot fully open or close. An increased travel may mean that the flow regulator 16, its seals, coupler 28, or actuator 20 has failed.

[0176] (iii) Whether the return duration (e.g., time information 98) exceeds a certain limit threshold, such as approximately 25 seconds. A longer return time may indicate increased friction or failure of the return spring 30 of actuator 20. It may also relate to the safety standards of the flow control device 12 in fire emergencies, namely that the flow regulator 16 should always move to the closed position within a certain permissible time limit.

[0177] At 104 ( Figure 10 Further analysis of current KPIs is needed to determine their trends compared to historical KPIs and, optionally, to projected KPIs (discussed later). For example, the analysis may involve one or more, or all, of the following:

[0178] (i) Whether the size of the first “hysteresis” window 52 has changed, for example, whether the corner width has increased. A change in the first hysteresis window 52 may indicate that the actuator 20 is currently defective or is becoming defective. Optionally, it may be determined whether the increase in the corner width of the first window is accompanied by a similar increase in the width of other windows.

[0179] (ii) Changes in the local peak 56 related to the seal, such as changes in the height and / or angular position of peak 56 and / or changes in the calculation of the integral.

[0180] (iii) Trend of maximum torque (88, Figure 11 Is there an abnormal increase? It can also determine if the torque is predicted to exceed the maximum permissible torque of 64 within a certain timeframe or usage cycle.

[0181] This could also be a problem with actuator 20.

[0182] (iv) Standard deviation Figure 11 (92) Whether it increases abnormally in one or more regions, for example, in the third window 58. An increase in the standard deviation may indicate wear, for example, in the actuator 20.

[0183] (v) Whether the gradient calculated for the fourth window 60 is changing.

[0184] (vi) Spring return value calculated based on the difference between torque values ​​( Figure 11 Is the 90% in the figure changing?

[0185] (vii) Range of travel angles Figure 11 Is 96 in the middle changing?

[0186] (viii) Return time of window 62 ( Figure 11 Is the 98% in the range changing, especially increasing significantly?

[0187] The above analysis and diagnosis can be achieved through appropriate automation techniques, such as one or more of machine learning, neural networks, fuzzy logic networks, and artificial intelligence systems. Parameters can be evaluated in combination to refine the distinction between the presence (actual or impending) of a fault in actuator 20 or flow regulator 16.

[0188] Figure 11The values ​​and trends of KPI parameter 80 are shown, which individually and / or in combination characterize the performance of the flow control device 12 and can reveal or diagnose actual and impending faults. Figure 11 In the diagram, the left column identifies values / trends related to faults in actuator 20, and the right column identifies values / trends related to faults in flow regulator 16. Upward arrows indicate value increases. Horizontal arrows indicate value changes that are not expected and / or irrelevant. Multi-directional arrows indicate that any change in value may be relevant. Although a single set of trend values ​​is shown, multiple trends associated with various faults in the actuator and / or flow regulator can optionally be provided or learned through machine learning. Different trends may optionally refer to different groups or subgroups of KPI parameters 80.

[0189] Figure 12-17 This demonstrates how to interpret KPI parameter 80 in actual testing to diagnose faults.

[0190] In the first example, the way the parameter value changes with usage (represented by the loop count) is... Figure 12 and 13 The description is provided below. The cycle count is displayed on the horizontal axis. Each parameter line is composed of... Figure 11 The same reference numerals are used in the figures. In particular, Figure 12 The changes in maximum torque information 88 from the third window 58 are shown; the changes in standard deviation 92 are represented by the dashed line adjacent to line 88; the changes in return time 98 from the fifth window 62; and the changes in hysteresis torque 84 from the first window 52. Figure 13 The changes in range information 96 are displayed; the changes in spring torque (rising feather) 90 are displayed; and the changes in the integral 94 of sealing peak 56 are displayed.

[0191] refer to Figure 12 At approximately 80K cycle counts, the first indication of a fault is clearly seen from the abnormal offset 110 of the return time 98. Additional offsets in the return time 98 and maximum torque 88 are also detectable at three events 112. Typically, the integrals of maximum torque 88, return time 98, hysteresis torque 84 (indicated by arrow 114), spring torque 90, and sealing peak 94 (all indicated by arrow 116) all show an increasing trend. Reference Figure 14 These increases typically correspond to the trends indicated in the left column of the parameter table, indicating a failure of actuator 20. An impending failure is evident from the first indication of approximately 80K cycles, although actuator 20 may actually fail after approximately 110K cycles.

[0192] In fact, Figure 12 and 13The parameters shown represent actual test values ​​from a flow control device 12 with a faulty actuator featuring a worn bearing. Figure 12 It is also worth noting that the standard deviation of 92 is generally stable (indicated by arrow 118), but this does not affect other trends. Figure 13 It is also worth noting that the abnormal offset (120) in the travel range of 96 occurred at approximately 110K cycles, which would also be an anomaly that would trigger a warning.

[0193] In the second example, the way the parameter value changes with usage (represented by the loop count) is... Figure 15 and 16 The diagram is depicted in the middle. The cycle count is displayed on the horizontal axis. Each parameter row is represented by... Figure 11 The same reference numerals are used in the figures. In particular, Figure 15 The changes are shown in the return time 98 from the fifth window 62; the size 86 of the sealing peak 56 from the second window 54; the maximum torque information 88 from the third window 58; the standard deviation 92 represented by the dashed line adjacent to line 88; and the hysteresis torque 84 from the first window 52. Figure 16 The integral 94 of the sealing peak 56 is shown; the range information 96 is shown; and the spring torque (rising feather) 90 is shown.

[0194] refer to Figure 15 and 16 The fault indication is evident from the abnormal deviation of the sealing torque 86 (122) and the abnormal deviation of the position range 96 (124) at approximately 70K cycle counts. The calculated integral 94 also shows a decrease starting at approximately 70K cycles. Other parameters (e.g., maximum torque 88, standard deviation 92, and spring torque 90) remain generally flat. Reference Figure 17 This combination typically corresponds to the trend indicated in the right column of the parameter table, indicating a failure of the flow regulator 16. The impending failure becomes apparent even earlier, starting around cycle 65K, becoming very noticeable at cycle 70K, and continuing until the flow regulator stops working around cycle 75K.

[0195] In fact, Figure 15 and 16 The parameters shown represent actual test values ​​from the flow control device 12 with a faulty flow regulator 16, which was tested until it broke. Figure 15 Of particular note (as indicated by arrow 126) is that the maximum torque and standard deviation of 92 remain largely stable. Figure 15 It is also worth noting that the return time remained relatively stable until the flow actuator failed and could not travel the full return distance.

[0196] refer to Figure 18 The enhancements to the aforementioned techniques can take into account the time impact on KPI parameter 80. For example, the time impact can include one or more of the following:

[0197] (i) Environmental impact 128, such as:

[0198] a. Temperature. As the temperature increases, the resistivity of the coils in motor 22 also increases, causing a decrease in motor efficiency. The viscosity of the grease in transmission device 26 may decrease.

[0199] Temperature can typically shift or deflect performance curves relative to the vertical axis. However, taking temperature into account and compensating for the correspondingly higher values ​​on the performance curve can prevent high values ​​from being incorrectly interpreted as exceeding thresholds. For example, Figure 19 Arrow 132 shows the performance curve shifting upwards as temperature increases.

[0200] b. Fluid pressure. The amount of force required for actuator 20 to move flow regulator 16 may depend on the fluid pressure acting on flow regulator 16. Taking fluid pressure into account and compensating for correspondingly higher values ​​on the performance curve can prevent high values ​​from being incorrectly interpreted as exceeding a threshold. For example, Figure 20 The effect of airflow or wind on the flow regulator 16 is shown. The varying force on the regulator 16 can significantly affect the torque curve, potentially increasing torque in some areas and decreasing torque below the expected curve in others (see 134).

[0201] c. Dirt / Contamination. Similar to temperature and pressure, the degree of impurities in the fluid can also affect the behavior of the flow regulator 16, and the magnitude of the force required for the actuator 20 to move the flow regulator 16. Considering dirt or contamination can prevent high torque curve values ​​from being incorrectly interpreted as exceeding a threshold.

[0202] (ii) Aging Effects 130: The operational life of the control device 12 can be recorded, for example, by maintaining a count of the number of times the actuator 20 has been operated and / or the total operating duration of the motor 20, or by aggregating other parameters of usage. (See above regarding...) Figure 9 As discussed, the torque can be reduced from its initial high value as the actuator 20 breaks in.

[0203] refer to Figure 21 and 22 Further enhancements to analytical techniques can be achieved using adaptive techniques. Adaptive techniques may include one or both of the following:

[0204] (i) Predictive data model module 140, based on one or more of the following:

[0205] a. Parameters derived from the flow control device 12 (e.g., from the actuator 20 at the time of manufacture)

[0206] / or the actuator 20 when assembled into the flow regulator 16 and / or the control unit 12 once installed into the HVAC system (measurement);

[0207] b. Parameters derived from other control devices similar to flow control device 12. For example, these other control devices may be other devices in the same HVAC system, and / or

[0208] Or control devices 12) in other HVAC systems;

[0209] c. Environmental influences, such as temperature and / or pressure;

[0210] d. Effects of aging

[0211] (ii) Adaptive diagnostic module 142, which adaptively responds to fault information derived from other flow control devices 12, optionally including environmental and aging effects.

[0212] This enhanced analytics technology can respond to or be driven by data from other flow control modules 12. The predictive data model module 140 can generate data modules representing how the flow controller 12 is expected to perform, based on information from outside the flow controller 12 itself. Similarly, the diagnostic module 142 can perform fault diagnosis based on fault information derived from other flow control devices 12.

[0213] refer to Figure 1 Predictive analysis can be performed in processing system 40, which is capable of receiving signals from multiple flow control devices 12, optionally in the same HVAC system 10, and / or optionally in multiple different HVAC systems. Controller 32 is operable to perform simpler onboard analysis on the flow control devices 12. The characteristics of the onboard analysis can be updated and / or adjusted based on information available to processing system 40, for example, using one of the communication channels or portable device 42.

[0214] also, Figure 1Actuator 12 is shown, which includes an interface module 144 that communicates with or forms part of controller 32. Interface module 144 includes a control interface 146 for interfacing with HVAC system controller 38, and / or a data model interface 148 for receiving data model information 48 and storing the data model in flow control device 12, and / or a diagnostic interface 150 for receiving and transmitting diagnostic information. Diagnostic information may include calculated KPI parameters 80, and / or signals from sensors 34 and 36 for remote processing, and / or the results of diagnostic tests for identifying actual and / or impending faults, and optionally for distinguishing between actual and impending faults in actuator 20 or flow regulator 16.

[0215] Figure 23a and 23b The parameters of the flow control unit 12 are shown to be set and used according to the manufacturing and installation method of the control unit 12. The process is divided into several parts: a first (“manufacturing”) stage 160, representing the production of a new actuator 20; an optional second (“damper assembly”) stage 162, in which the new actuator 20 is assembled into the new flow regulator 16 to complete the manufacturing of the new flow control device 12; a third (“installation”) stage 164, in which the components are physically installed into the HVAC system; a fourth (“integration and commissioning”) stage 166, in which the components are made operational within the HVAC system; and a fifth (“testing”) stage 168, in which the functionality of the flow control device 12 is tested and actual or impending failures are diagnosed. This process is described with respect to a flow regulator 16 in the form of a fireproof damper, as an example of a flow control unit 12 that needs to meet high safety standards. However, the same process can be applied to other types of flow regulators 16. The terms “flow regulator” and “damper” are interchangeable and can be used interchangeably.

[0216] During the first production phase 160, step 201 represents the manufacture of the new actuator 20, followed by testing of the actuator 20 in step 202. During step 202, characteristic parameters of the actuator 20 itself can be recorded for the data model, providing a separate view of the operation of the actuator 20, even outside of a hysteresis window. This information can be recorded by establishing a birth certificate and / or other unique identifier for a specific actuator 20. This information can be stored as part of the birth certificate and / or in a separate database accessible through the birth certificate. For example, the information can be stored in the remote processing system 40. Alternatively or additionally, the information can be input via the model interface 148 and stored within the actuator controller 32.

[0217] After the production of actuator 20, the process can take one of three possible paths 180, 182 or 184, depending on how actuator 20 will be used.

[0218] The first path 180 represents the production of a new flow control unit 12 using actuator 20 in the second assembly stage 162. The second assembly stage 162 can be performed by the same manufacturer as the first stage 160 or a different manufacturer (e.g., in an OEM production process). Step 204 represents the assembly of actuator 20 into a new flow regulator 16 in the form of a fireproof damper to form the new unit 12. In step 205, the assembled actuator 20 and damper (flow regulator 16) are tested together. During step 205, characteristic parameters of actuator 20 and damper can be recorded together for data modeling, providing a view of the operation of device 12 when it is new. This information can be recorded and / or associated with a birth certificate. The information can optionally be stored in the remote data processing system 40 and / or actuator controller 32 in a similar manner to that described above.

[0219] Referring again to the first path 180, the flow control device 12 is physically installed in the HVAC system 10 in the third installation phase 164. Step 206 represents the step of installing the flow control device 12 as a combined unit.

[0220] In the fourth installation / commissioning phase 166, the necessary testing and integration of the flow control device 12 are performed. Step 207 represents the data processing steps for assigning the flow control device identifier within the HVAC system. Step 208 represents testing the flow control device 12 after installation. In addition to recording correct operation, step 208 may also include recording characteristic parameters of the device 12 in its installed state for the data model. This information may be recorded along with and / or associated with a birth certificate. The information may optionally be stored in the remote data processing system 40 and / or actuator controller 32 in a similar manner as described above.

[0221] If a new HVAC system is installed in the building, step 209 is optional. A full system test can be performed to verify and document correct operation.

[0222] The second path 182 is similar to the first path 180, except that the actuator 20 and the damper (flow controller 16) are installed in the HVAC system as separate new devices rather than being "manufactured" as a unit. The second path 182 therefore skips the second assembly stage 162. Instead, in the third installation stage 164, the damper is installed in step 210, followed by the actuator 20 in step 211.

[0223] Referring again to the second path 182, during the fourth installation / commissioning phase 166, the flow control device 12 is tested and integrated in a manner similar to that already described. Step 212 (similar to step 207) represents a data processing step that assigns the flow control device identifier within the HVAC system. Step 213 is an additional step that tests and records the correct operation of the actuator 20 and damper together. Step 214 (similar to step 208) represents testing the flow control device 12 as part of the HVAC system. In addition to recording correct operation, steps 213 and / or 214 may also include recording characteristic parameters of the device 12 in its installed state for a data model. This information may be recorded and / or associated with a birth certificate. The information may optionally be stored in the remote data processing system 40 and / or actuator controller 32 in a manner similar to that described above.

[0224] The third path 184 is somewhat similar to the second path 182, except that the new actuator 20 is retrofitted to an already installed damper (flow regulator 16) in the HVAC system, for example, to replace a previously defective actuator. The third path 184 thus proceeds directly to the third installation stage 164, where the actuator 20 is installed with the existing damper in step 215 (similar to step 211). The third path 184 continues to the fourth integration / commissioning stage 166, where the process is similar to that of the second path 182. Step 216 (similar to steps 207 and 212) represents the data processing steps of assigning the flow control device identifier within the HVAC system. Step 217 (similar to step 213) represents testing and recording the correct operation of the actuator 20 with the damper. Step 218 (similar to steps 208 and 214) represents testing the flow control device 12 as part of the HVAC system. In addition to recording correct operation, steps 217 and / or 218 may also include recording characteristic parameters of the device 12 in its installed state for data modeling. This information may be recorded together with and / or associated with the birth certificate. The information may optionally be stored in the remote data processing system 40 and / or the actuator controller 32 in a manner similar to that described above.

[0225] Test phase 168 represents subsequent testing of the HVAC system 10, optionally particularly the flow control device 12. Testing can be performed through periodic checks, for example, to comply with local laws. Alternatively, testing can be performed during periodic maintenance. Alternatively, the control device 12 can monitor its operational performance as part of normal operation when actuator 20 is commanded to move and / or when periodic self-tests are commanded by the HVAC system controller 38 and / or actuator controller 32. Step 220 represents the actuator controller 32 generating a command to cause actuator 20 to drive the movement of the damper (flow regulator 16). Step 221 represents the controller 32 receiving signals from sensor 34 (and optionally 36). Step 222 represents a diagnostic of the flow control device 12 based on the sensor signals to determine the presence (actual or impending) of a fault and to distinguish whether the fault is in actuator 20 or in the damper (flow regulator 16). Step 223 represents replacement and / or maintenance of actuator 20 in the event of a detected actuator fault. The replacement will involve modifying the actuator 20 as described above.

[0226] The fourth integration / debugging phase 166 and / or the fifth testing phase 168 may optionally be performed with the assistance of the portable device 42. The portable device 42 may be a dedicated device or a mobile computing device running application software. The portable device 42 can communicate with the actuator controller 32 via any local or wide-area communication protocol. An example of a local protocol could be NFC (Near Field Communication), which can be equipped with both interface 144 and the mobile device 42. The portable device 42 may be configured to guide the operator through the process steps of the fourth phase 166 and / or the fifth phase 168 and display the results generated by the control device 12.

[0227] The portable device 42 can also be used to access reference and performance curves stored during the production phase of the actuator 20 and / or damper (flow regulator 16). Additionally or alternatively, the portable device 42 can be used to access pending and / or archived error and / or warning messages. Additionally or alternatively, the portable device 42 can be used to access documentation, such as specifications, datasheets, or installation instructions, for the reference control device 12 or one of its components (e.g., actuator 20 and / or damper).

[0228] The portable device 42 can also be used to access documents relating to the installation location, such as building floor plans. The positioning or orientation determination of the portable unit 42 can be used to enhance the information provided (e.g., by indicating its location on the building floor plan).

[0229] The portable device 42 can also be used to control access to the control device 12.

[0230] It should be understood that the foregoing description is merely an illustration of preferred embodiments of the present invention, and many modifications and equivalents may be used within the scope and / or principles of this disclosure.

Claims

1. A method for controlling an HVAC system (10), comprising: - At least one flow regulator (16) includes an actuable element (18) for regulating the flow rate of fluid in the fluid path. - An electromechanical actuator (20) associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor (22) that drives a movable output member (24). - One or more sensors (34) associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors; - A controller (32) operatively connected to the actuator and the sensor. The method includes the following steps: i. Actuating the flow regulator described in (220); ii. Receive (221) signals from the one or more sensors; iii. Based on the signal received in step ii, determine (222) the actual or impending fault, wherein, - The actuator itself does not have a reference load curve or current curve (50a) without the flow regulator; and / or - Reference curve associated with the flow regulator itself without the actuator Used to identify actual or impending faults; iv. Inform the operator of the HVAC system of the actual or impending failure; The feature is that, in step iv, the following actual or impending faults are distinguished: -The actuator (20); and -The flow regulator (16).

2. The method of claim 1, wherein, The HVAC system also includes a mechanism, optionally a lever mechanism, which operatively connects the output component to the flow regulator.

3. The method of claim 1 or 2, wherein, The actual or impending failure of the flow regulator (16) is selected from the group consisting of: deformed damper sleeve; worn bearing; improperly fixed bearing; worn gasket; damaged damper blade; blockage of the actuating element of the flow regulator.

4. The method of any one of claims 1 to 3, wherein, The actual or impending failure of the actuator (20) is selected from the group consisting of: a defective or worn bearing for the output component; a defective or worn output gear; a defective actuator mount; a defective motor; a defective motor bearing; a defective connection to the flow regulator; a non-attached connection to the flow regulator; a defective return spring; and a defective supercapacitor that supplies power to the actuation at a predetermined position in the event of a power failure. A defective battery that supplies power to the actuation at a predetermined position in the event of a power outage; Defective electronic circuits.

5. The method of any one of claims 1 to 4, wherein, The HVAC system also includes one or more sensors (34, 36), which are selected from the group consisting of: temperature sensor; humidity sensor; flow sensor; wind speed sensor; air / fluid quality / contamination sensor; viscosity sensor; concentration sensor.

6. The method of any one of claims 1 to 5, wherein, The number of cycles and / or the count of direction changes of the flow regulator (16) and / or the total operating time and / or the total stroke; and / or the number of cycles and / or the count of direction changes of the actuator (20) and / or the total operating time and / or the total stroke are recorded.

7. The method of any one of claims 1 to 6, wherein, In step iii, the actual or impending fault is determined, while also taking corrective compensation into consideration: - The flow rate of the medium through the flow regulator (16); -The operating temperature of the actuator (20); -The temperature at which the flow regulator (16) operates; - Historical records of actuator torque and / or actuator temperature and their combinations.

8. The method of any one of claims 1 to 7, wherein, In step iii, - Reference load or current profile of the actuator when operatively connected to the flow regulator (50b; 50c) Used to identify actual or impending failures.

9. The method of any one of claims 1 to 8, wherein, In step ii, - Load curves and / or current curves when the flow regulator is actuated or released; and / or - The position of the output component over time when the flow regulator is actuated or released; and / or - The integral calculated based on the load curve and / or the current curve when the flow regulator is actuated or released; and / or - The position of the output component at the maximum torque amplitude and / or the maximum current amplitude and / or the maximum amplitude of the calculated load derivative and / or the maximum amplitude of the calculated current derivative; and / or - The position of the output component in the open and / or closed position of the flow regulator; and / or - The output component is located at the end of the stroke range of the flow regulator; - The derivative of the load and / or current when the flow actuator approaches the open and / or closed position; and / or - Variations in load and / or current within the predetermined operating range; and / or - The speed at which the actuator and / or the flow regulator moves when the flow regulator is actuated; and / or - The return time of the return mechanism operating in the automatic return valve; It was recorded.

10. The method of any one of claims 1 to 9, wherein, In step iv, the hysteresis of the actuator and / or lever mechanism is used to distinguish between a failure of the actuator (20) and the flow regulator (16).

11. A method for setting up an HVAC system, comprising: - At least one flow regulator (16) includes an actuable element (18) for regulating the flow rate of fluid in the fluid path. - An electromechanical actuator (20) associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor (22) that drives a movable output member (24). - One or more sensors (34) associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors; - A controller (32) operatively connected to the actuator and the sensor. The method includes the following steps: i. Actuate the flow regulator (16); and ii. Actuate the actuator (20) itself, while the output member (24) is not operatively connected to the flow regulator; iii. During steps i and ii, receive signals from the one or more sensors (34); iv. Based on the signals received in step iii, determine the actual or impending fault, including diagnosing the impending fault; v. To indicate the actual or impending failure; The feature is that, in step v, the following actual or impending faults are distinguished: -The actuator (20); and -The flow regulator (16).

12. The method of claim 11, further comprising the step of: - Based on the signal received in step iii, provide the user with guidance on how to overcome the fault.

13. The method of any one of claims 1 to 12, wherein, The steps to identify an actual or impending fault include diagnosing the actual fault.

14. The method of any one of claims 1 to 13, wherein, The steps to identify an actual or impending failure include diagnosing both the actual and impending failures.

15. The method of any one of claims 1 to 14, wherein, The steps to determine an actual or impending failure include: - Determine whether the signals received from the one or more sensors correspond to an impending fault; and - Determine whether the signals received from the one or more sensors correspond to an actual fault.

16. The method of any one of claims 1 to 15, wherein, The steps for indicating an actual or impending fault include distinguishing between an actual fault and an impending fault.

17. A method for controlling an HVAC system (10), comprising: - At least one flow regulator (16) includes an actuable element (18) for regulating the flow rate of fluid in the fluid path. - An electromechanical actuator (20) associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor (22) that drives a movable output member (24). - One or more sensors (34) associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors, wherein at least one of the one or more sensors (34) is a torque sensor; - A controller (32) operatively connected to the actuator and the sensor. The method includes the following steps: i. Actuating the flow regulator described in (220); ii. Receive (221) signals from the one or more sensors; iii. Based on the signal received in step ii, determine (222) the actual or impending fault; iv. Inform the operator of the HVAC system of the actual or impending failure; Its features are, - In step iv, distinguish between the following actual or impending faults: -The actuator (20); and -The flow regulator (16); and - In step iii, the torque curve (50) is divided into certain operating windows; - In step iii, a diagnosis is performed based on a data model (48) that includes key performance indicators (80), which include one or more of the following, optionally at least some and / or at least most and / or all of them: - First torque information (84) associated with the first operation window (52); - Second torque information (86) associated with the second operation window (54); -Third torque information (88) associated with the third operation window (58); - Fourth torque information (90) is associated with the difference between the torque at the start of the first operation window (52) and the end of the third operation window (58); - Fifth torque information (92) associated with the distribution of torque during the third operating window (58); -Sixth torque information (94) associated with the calculated integral of the peak (56) in the second operation window (54); - Full range information (96) associated with the operating range of the control device (12); and - Time formation (98) associated with the duration of the fifth operation window (62).

18. The method of claim 17, wherein in step iii, one or more key performance indicators (80) from one or more previously run operations are used in the form of historical data, optionally weighted averages, to enable tracking of changes and / or trends in the key performance indicators (80).

19. A method for controlling an HVAC system (10), comprising: - At least one flow regulator (16) includes an actuable element (18) for regulating the flow rate of fluid in the fluid path. - An electromechanical actuator (20) associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor (22) that drives a movable output member (24). - One or more sensors (34) associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors; - A controller (32) operatively connected to the actuator and the sensor. The method includes the following steps: i. Actuating the flow regulator described in (220); ii. Receive (221) signals from the one or more sensors; iii. Based on the signal received in step ii, determine (222) the actual or impending fault; iv. Inform the operator of the HVAC system of the actual or impending failure; Its features are, - In step iv, distinguish between the following actual or impending faults: -The actuator (20); and -The flow regulator (16); and - In step ii, record: - The integral calculated based on the load curve and / or current curve when the flow regulator is actuated or released; and / or - The position of the output component at the maximum torque amplitude and / or the maximum current amplitude and / or the maximum amplitude of the calculated load derivative and / or the maximum amplitude of the calculated current derivative; and / or - The derivative of the load and / or current when the flow actuator approaches the open and / or closed position; and / or - Variations in load and / or current within the predetermined operating range.

20. A method for controlling an HVAC system (10), comprising: - At least one flow regulator (16) includes an actuable element (18) for regulating the flow rate of fluid in the fluid path. - An electromechanical actuator (20) associated with the flow regulator to actuate the flow regulator, wherein the actuator includes an electric motor (22) that drives a movable output member (24). - One or more sensors (34) associated with each actuator, wherein the sensors are selected from the group consisting of load sensors, force sensors, torque sensors, current sensors, voltage sensors, power sensors, speed sensors and position sensors; - A controller (32) operatively connected to the actuator and the sensor. The method includes the following steps: i. Actuating the flow regulator described in (220); ii. Receive (221) signals from the one or more sensors; iii. Based on the signal received in step ii, determine (222) the actual or impending fault; iv. Inform the operator of the HVAC system of the actual or impending failure; Its features are, - In step iv, distinguish between the following actual or impending faults: -The actuator (20); and -The flow regulator (16); and - In step iii, the actual or impending fault is determined, while also taking corrective compensation into consideration: -The operating temperature of the actuator (20); -The temperature at which the flow regulator (16) operates; - Historical records of actuator torque and / or actuator temperature and their combinations.

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