Condenser blockage detection method and system

Abstract

The invention relates to a condenser blockage detection method and system. A method for detecting condenser clogging of a cooling system may include determining a current state of the cooling system. The method may also include collecting a set of measurement data, wherein the set of measurement data may include at least one of pressure data, ambient air temperature data, condenser temperature data, humidity data, thermal image data, or normal camera image data. The method may also include analyzing the collected set of measurement data to detect whether a condenser of the cooling system is at least partially blocked or clean.

Description

Cross-references to related applications

[0001] This disclosure claims the benefit of U.S. Provisional Application No. 63 / 699,417, filed September 26, 2024, pursuant to 35 USC §119(e), which is incorporated herein by reference in its entirety. Technical Field

[0002] This disclosure generally relates to the field of cooling systems, and more specifically to methods and systems for detecting condenser blockage. Background Technology

[0003] The goal of a cooling unit is to absorb heat generated by the server and transfer it to the outside of the server's physical location. Typically, the heat is collected so that it is released into the environment. To have the ability to absorb heat, a cooling unit should have a device for circulating refrigerant. This refrigerant should then be cooled in an outdoor condenser, where the collected heat is dissipated into the surrounding environment. When the cooling unit is operating normally, the condenser is clean, allowing the cooling unit to have its maximum heat dissipation capacity. However, if the condenser becomes clogged (or at least partially clogged) for some reason, heat transfer becomes less efficient and requires higher airflow (e.g., a higher condenser fan ramp). Since the energy consumption of the condenser fan is a function of the condenser fan ramp, even a small increase in the condenser fan ramp can result in a significant difference in energy consumption.

[0004] Therefore, a system and method are needed to address one or more shortcomings of existing methods. Summary of the Invention

[0005] According to one or more embodiments of this disclosure, a method for detecting condenser blockage in a cooling system is disclosed. In one embodiment, the method includes: determining the current state of the cooling system; collecting a set of measurement data, wherein the set of measurement data includes at least one of pressure data, ambient air temperature data, condenser temperature data, humidity data, thermal images, or images from a conventional camera; and analyzing the collected set of measurement data to detect whether the condenser of the cooling system is at least partially blocked or clean.

[0006] According to one or more embodiments of this disclosure, a cooling system is disclosed. In one embodiment, the cooling system includes: a condenser; a condenser fan; an evaporator; an evaporator fan; one or more continuous monitoring sensors; at least one of one or more temperature sensors, pressure sensors, or humidity sensors; and one or more controllers communicatively coupled to the condenser, the one or more continuous monitoring sensors, and at least one of one or more temperature sensors, pressure sensors, or humidity sensors. The one or more controllers include one or more processors, each processor including a set of program instructions configured to cause the processor to: determine the current state of the cooling system; collect a set of measurement data, including at least one of pressure data, ambient air temperature data, condenser temperature data, humidity data, thermal images, or images from a conventional camera; and analyze the collected measurement data to detect whether the condenser of the cooling system is at least partially blocked or clean.

[0007] It should be understood that the foregoing general description and the following detailed description are merely exemplary and illustrative, and do not necessarily limit the scope of this disclosure. The subject matter of this disclosure is illustrated in conjunction with the accompanying drawings, which are included in and form part of this specification. Description and Drawings Figure 1 It serves to explain the principles underlying this disclosure. Attached Figure Description

[0008] By referring to the accompanying drawings, those skilled in the art can better understand the various advantages of this disclosure.

[0009] Figure 1 This is a simplified conceptual diagram of the cooling system.

[0010] Figure 2 This is a simplified block diagram of a condenser fouling detection system according to one or more embodiments of the present disclosure.

[0011] Figure 3 This is a flowchart depicting a method or process for detecting condenser blockage according to one or more embodiments of the present disclosure.

[0012] Figure 4 This is a simplified conceptual diagram of a cooling system according to one or more embodiments of the present disclosure.

[0013] Figure 5 It is a graph of pressure difference versus condenser fan speed according to one or more embodiments of this disclosure.

[0014] Figure 6It is a graph of the condenser ambient temperature relative to the ambient air temperature according to one or more embodiments of the present disclosure.

[0015] Figure 7 This is a simplified conceptual diagram of a cooling system in operation according to one or more embodiments of the present disclosure.

[0016] Figure 8A This is a conceptual diagram of a continuous monitoring system including a common camera device according to one or more embodiments of the present disclosure.

[0017] Figure 8B This is a conceptual diagram of a continuous monitoring system including a common camera device according to one or more embodiments of the present disclosure.

[0018] Figure 9 This is a flowchart depicting a method or process for condenser blockage detection based on a calculation method according to one or more embodiments of the present disclosure. Detailed Implementation

[0019] The disclosed subject matter will now be referred to in detail, as shown in the accompanying drawings.

[0020] Embodiments of this disclosure relate to condenser blockage detection systems and methods. For example, the condenser blockage detection system and method can be configured to automatically detect whether a cooling unit is operating with a clean condenser or a partially blocked condenser. Depending on the state of the cooling unit, the condenser blockage detection system can be configured to perform different levels of intervention. Furthermore, upon detecting condenser blockage, the system and method can generate a warning / alarm / signal to prompt condenser cleaning.

[0021] As discussed earlier in this article, the goal of a cooling unit is to absorb the heat generated by the server and transfer such heat to the outside of the server's physical location. Typically, the heat is collected so that it can be released into the environment. To have the ability to absorb heat, a cooling unit should have a device for circulating refrigerant. This refrigerant should then be cooled in a condenser, where the collected heat is dissipated into the surrounding environment.

[0022] Figure 1 A cooling system 100 with a direct expansion (DX) cooling circuit having a pumped refrigerant economizer mode is shown. Figure 4A cooling system 100 is shown. System 100 includes an indoor unit 101 and an outdoor unit 103. The outdoor unit 103 includes, but is not limited to, a condenser 102, a condenser fan 104, etc., installed externally to a building, such as on a roof, and the indoor unit 101 includes an evaporator 106, an evaporator fan 108, an expansion valve 111 (or expansion device), a sensor 208, a sensor 210, a compressor 109, and a check valve 113, installed internally to a building, such as a data center. When the cooling system 100 operates normally, such as... Figure 1 As shown, the condenser 102 is clean, allowing the cooling system 100 to have maximum heat dissipation capacity. However, when the system 100, particularly the condenser 102, becomes clogged (or at least partially clogged), as... Figure 4 As shown, system 100 malfunctions, heat transfer becomes less efficient, and higher air circulation is required (e.g., higher condenser fan ramp). Since the energy consumption of condenser fan 104 is a function of condenser fan ramp, even a small increase in condenser fan ramp can lead to a large difference in energy consumption.

[0023] A data center may include one or more cooling systems 100 installed. In some cases, each individual cooling system 100 may be interconnected. In this respect, the individual systems 100 share information and communicate, enabling them to be configured to operate collaboratively. Additionally, in some cases, the cooling systems 100 may be configured in an N+1 configuration. For example, in a non-limiting example, a data center may require at least 10 cooling systems to function fully, resulting in 10+1 units installed. In this respect, the data center will still operate without any problems during maintenance.

[0024] Figure 2 A simplified block diagram of a system 200 for detecting condenser blockage according to one or more embodiments of this disclosure is shown. It is contemplated herein that system 200 can be applied to any suitable type of condenser commonly used in cooling systems, such as air-cooled or dry-cooled condensers.

[0025] One or more condensers 102 may be configured to supply cooled liquid (or air) to the cooling system 100. In addition, one or more condensers 102 may transfer heat from the return fluid (or return air) from the cooling system 100 to a cooler medium, such as ambient air.

[0026] Cooling system 100 may include one or more refrigerant pumps 110 (or refrigerant units). One or more refrigerant pumps 110 may supply refrigerant to cooling system 100. In some cases, cooling system 100 may be a phase change refrigerant air conditioning system with a refrigerant compressor 109, such as a direct expansion (DX) system. Condenser 102 may be coupled to refrigerant pump 110. For example, refrigerant pump 110 may be coupled to a portion of the cabinet of condenser 102. Phase change refrigerant may be circulated by compressor 109 through condenser 102, expansion valve 111 (or expansion device), coils (or evaporator 106), and back to compressor 109 of cooling system 100.

[0027] As discussed earlier herein, condenser 102 can be installed externally. For example, condenser 102 can be installed on a roof or a mezzanine above a roof. In this respect, condenser 102 can transfer heat from the return fluid from cooling system 100 to a cooler medium, such as ambient air. One or more components of condenser 102 can be configured to be housed in one or more cabinets.

[0028] The condenser 102 may be in the form of one or more coils. In some cases, the condenser 102 may include a "V-coil" assembly (or "V-condenser block") comprising one or more "V-shaped" coils. In other cases, the condenser 102 may include a flat coil assembly comprising one or more flat coils. It is contemplated herein that the condenser 102 may include any type of coil, and therefore the foregoing description and associated drawings should not be construed as limiting the scope of this disclosure.

[0029] One or more fans 104 may be arranged close to the condenser 102 so that air can be drawn in (e.g. by one or more fans 104) Figure 1 (As indicated by the arrow in the image).

[0030] The cooling system 100 may also include one or more controllers 202, which include one or more processors 204 and memory 206. As will be discussed further herein, one or more controllers 202 may be configured to automatically detect whether the cooling system 100 is operating with a clean condenser 102 or a partially clogged condenser 102. For example, one or more controllers 202 may be configured to perform a level-based intervention approach when a partially clogged condenser is detected. For example, when a condenser clog is detected, one or more controllers 202 may be configured to generate a warning / alarm / signal to prompt condenser cleaning. In this respect, the cooling system 100 is able to maintain the required cooling demand while also operating with lower possible energy consumption, thereby allowing for higher coefficient of performance (COP) operation.

[0031] One or more controllers 202 can be configured to be coupled to various sensors 208, 210, 212, 214, 216, 218, such as outdoor temperature sensors and pressure sensors.

[0032] For example, the condenser 102 may include (or be coupled to) one or more temperature sensors 208 configured to measure ambient air temperature and provide such measurement results to one or more processors 204.

[0033] As another example, the condenser 102 may also include (or be coupled to) one or more pressure sensors 210, which are configured to measure pressure differentials and provide such measurements to one or more processors 204.

[0034] As another example, the condenser 102 may include (or be coupled to) one or more humidity sensors 212 configured to measure ambient air temperature and provide such measurements to one or more processors 204.

[0035] In some cases, controller 202 may be coupled to one or more continuous monitoring sensors 214. For example, as will be discussed further herein, continuous monitoring sensor 214 may include one or more thermal imaging devices 216 configured to capture thermal image data. As another example, as will be discussed further herein, continuous monitoring sensor 214 may include one or more general imaging devices 218 (or red / blue / green (RBG) cameras) configured to capture general image data.

[0036] One or more controllers 202 may be communicatively coupled to one or more user devices 220, including a display device 222 and one or more user input devices 224. One or more user devices 220 may be integrated within or coupled to the cooling system 100 (or external to the cooling system 100). One or more user devices 220 may be configured to receive one or more control signals from one or more controllers 202 to generate an alarm based on a current state associated with a predetermined threshold. For example, one or more user devices 220 may display a visual alarm on the display device 222. As another example, one or more user devices 220 may emit an audible alarm through a speaker (e.g., an integrated speaker, a remote speaker, etc.) of the user device 220. As another example, one or more user devices 220 may generate a haptic alarm on the user device 220.

[0037] Figure 3 A simplified flowchart depicting a method or process 300 for performing condenser blockage detection according to one or more embodiments of the present disclosure is shown.

[0038] In step 302, the state of the cooling system can be determined. For example, when there is more than one cooling system or cooling unit, such as using more than one condenser 102, one or more processors 204 can be configured to determine the state of a series (or more) cooling systems. For example, one or more processors 204 can be configured to determine whether the cooling system 100 is off 302A, in forced operation 302B, or on 302C.

[0039] In step 304, when it is determined that at least one cooling unit (or system) in a series of cooling units is off (302A), the condenser fan speed can be adjusted. It is anticipated herein that, since cooling unit 100 is not operating, such as Figure 4 As shown, the refrigerant circulation equipment for a particular cooling unit may also be inactive, thus eliminating the need for condenser operation. However, in this case, the condenser fan speed can be overridden. For example, one or more processors 204 can be configured to generate one or more signals configured to adjust the condenser fan speed. For example, one or more signals can be configured to cause the condenser fan to operate at a predetermined frequency for a predetermined time period. In a non-limiting example, the fan speed may be adjusted every 30 seconds.

[0040] In step 306, while adjusting the fan speed, one or more measurement results can be recorded during a predetermined time period. For example, one or more processors 204 can be configured to receive one or more measurement results during the predetermined time period of adjusting the fan speed.

[0041] One or more measurements may include recordable differential pressure, fan speed, ambient air temperature, humidity, etc. For example, the condenser may include one or more differential pressure sensors configured to measure the differential pressure in the condenser and provide such measurements to one or more processors 204. For example, the condenser may include (or be coupled to) one or more temperature sensors configured to measure the ambient air temperature and provide such measurements to one or more processors 204.

[0042] In step 308, the measurement results from step 306 can be stored in memory as a baseline for future reference.

[0043] In step 310, steps 304 and 306 can be repeated to obtain actual measurement data (e.g., a set of measurement data), and in step 312, this data can be analyzed to compare with the stored baseline data from step 308. For example, the difference between the actual measurement data and the baseline can be used to detect condenser fouling.

[0044] Figure 5 A graph 500 depicting condenser fan speed and pressure differential for detecting blockage is shown according to one or more embodiments of this disclosure.

[0045] If the actual measured data is higher than the baseline (or increases above a predefined threshold), condenser blockage can be detected (in step 314). For example, as Figure 5As shown in curve 500, condenser blockage can be detected if the pressure difference based on the condenser fan speed is greater than the baseline. Upon detection of condenser blockage, in step 316, one or more signals can be generated to notify of potential condenser fouling. For example, one or more processors 204 can be configured to generate one or more warnings to alert of potential condenser fouling. For example, one or more processors 204 can be configured to generate one or more control signals configured to cause a display device (or other user device) to display a warning notification (or pop-up) regarding potential condenser fouling. As another example, one or more processors 204 can be configured to generate one or more alarms to alert a user of potential condenser fouling. For example, one or more processors 204 can be configured to generate one or more control signals configured to cause a display device (or other user device) to generate an alarm (e.g., an audible alarm, vibration notification, etc.) to alert the user of potential condenser fouling. As another example, one or more processors 204 may be configured to generate one or more control signals, which are configured to cause the cleaning subsystem to perform condenser cleaning.

[0046] If the actual measured data is less than or equal to the baseline (or a predefined threshold), then condenser blockage may not be detected (in step 318). For example, as Figure 5 As shown in curve 500, if the pressure difference based on the condenser fan speed is less than the baseline, then no condenser blockage can be detected (e.g., a clean condenser can be detected).

[0047] In step 320, when it is determined that a series of cooling units (e.g., there are N+1 cooling units) are operating in a cooperative working mode where deliverable cooling capacity can be switched among them (302B), at least one of the cooling units in the series can be selected to be excluded. For example, in a non-limiting example, there may be 5 units, and each unit may have a specific identifier (ID) (e.g., 1, 2, 3, 4, 5). In this example, one or more processors 204 may be configured to identify the lowest ID and the time of the last check. Upon identifying the lowest ID and the time of the last check, one or more processors 204 may be configured to exclude the first unit (e.g., 1) from the cooperative working mode, such that units 2, 3, 4, 5 will operate in the cooperative working mode and provide precise cooling, and unit 1 will perform its operation. When complete, unit 1 will be reintroduced into the cooperative working mode, and unit 2 will be excluded. Continuing with this example, unit 2 is then checked, and units 1, 3, 4, 5 provide precise cooling for each of the corresponding units, etc. In this regard, the remaining units will adjust their operation according to the current heat load to provide the target cooling capacity.

[0048] In step 322, the compressor speed of the excluded unit can be adjusted to fix the compressor speed. It is contemplated herein that the fixed compressor speed can be at any predetermined frequency. For example, the compressor speed can be fixed at 80%. As another example, the compressor speed can be fixed at 100%.

[0049] In step 324, the evaporator fan speed of the excluded unit can be adjusted to control at least one of the suction pressure or temperature. For example, one or more processors 204 can be configured to generate one or more control signals configured to adjust the fan 108.

[0050] In step 326, the condenser fan speed of the excluded unit can be adjusted. For example, the condenser fan speed can be adjusted so that the fan speed is 100%. For example, one or more processors 204 can be configured to generate one or more control signals configured to adjust the fan 104 of the condenser 102 to 100% (or any other predetermined frequency level).

[0051] In step 328, measurement data may be collected. For example, compressor speed, condenser speed, suction pressure / temperature, ambient air temperature, condensing pressure / temperature, etc., may be collected. For example, one or more processors 204 may be configured to receive one or more measurement results from corresponding sensors (or monitoring devices) associated with compressor speed, condenser speed, suction pressure / temperature, ambient air temperature, condensing pressure / temperature, etc., and store them in a memory.

[0052] In step 330, the difference between the actual measured data and the baseline can be used to detect condenser fouling. For example, in a non-limiting example, a range of ambient temperatures can be selected, such as low, medium, and high. In this example, one or more controllers 202 can be configured to monitor the ambient air temperature. If the ambient air temperature is within a given temperature range, such as ±1 K for a low ambient air temperature, the cooling system 100 can be allowed to execute a forced operating mode (302B). The measurement results are then compared to a reference baseline.

[0053] Figure 6 A graph 600 depicting changes in ambient air temperature and condensation ambient temperature to detect blockage is shown according to one or more embodiments of the present disclosure.

[0054] If the actual measurement data is higher than the baseline (or greater than a predefined threshold), condenser blockage can be detected (in step 332). For example, as Figure 6 As shown in curve 600, if the temperature change based on the ambient air temperature is greater than the baseline, condenser blockage can be detected. In this regard, a higher difference between the condensing temperature and the ambient air temperature will indicate that the condenser is in a worse condition (e.g., blockage or fan malfunction).

[0055] Upon detection of condenser blockage, in step 334, one or more signals may be generated to notify of potential condenser fouling. For example, one or more processors 204 may be configured to generate one or more warnings to alert the user of potential condenser fouling. As another example, one or more processors 204 may be configured to generate one or more alarms to alert the user of potential condenser fouling. As yet another example, one or more processors 204 may be configured to generate one or more control signals configured to cause the cleaning subsystem to perform condenser cleaning. In a non-limiting example, if a difference greater than a defined threshold exists, one or more controllers 202 may be configured to issue a message notifying of potential condenser blockage.

[0056] This document anticipates that alarms may include any suitable type of alarm, such as, but not limited to, audio alarms, visual alarms, tactile alarms (e.g., vibration), etc.

[0057] If the actual measured data is less than or equal to the baseline (or lower than the baseline with a predefined threshold added), then condenser blockage may not be detected (in step 336). For example, as Figure 6 As shown in curve 600, if the temperature change based on the ambient air temperature is less than the baseline, then no condenser blockage can be detected (e.g., a clean condenser can be detected).

[0058] This document anticipates that a minimum required ambient air temperature can be used to ensure that high condenser fan speeds do not cause a significant drop in condensing pressure, which would result in operation beyond the envelope, an undesirable situation. The minimum required ambient air temperature can be supplied / provided by the user, customer, manufacturer, etc.

[0059] In step 338, when it is determined that one or more cooling units are operating (302C) (e.g., not shut down and not in cooperative operating mode), a continuous monitoring method may be performed, such as regarding... Figure 7 , Figure 8A , Figure 8B and Figure 9 The subject of discussion.

[0060] Overall reference Figure 7 , Figure 8A and Figure 8B The continuous monitoring method can utilize one or more condenser monitoring sensors 214.

[0061] For example, one or more condenser monitoring sensors 214 may include a thermal imaging device 216 configured to detect whether the cooling system 100 is operating with a clean condenser 102 or a partially blocked condenser 102.

[0062] The thermal imaging device 216 can be configured to monitor the temperature of the condenser coil. For example, images can be evaluated online or sent to a monitoring system performing the evaluation. (See reference...) Figure 7 If the condenser has one or more blocked areas (e.g., bright spots / dark spots) as indicated in image 700, a condenser blockage can be detected. It is anticipated that simply checking the temperature may not be sufficient for condenser blockage detection; therefore, one or more additional parameters can be used to determine if one or more condensers are blocked. For example, ambient air temperature and / or humidity data can be used in conjunction with temperature to detect condenser blockage. Additionally, wind direction, speed, and sunlight intensity, as well as other localized heat sources such as ventilation, can also be used as input.

[0063] As another example, one or more condenser monitoring sensors 214 may include a general-purpose camera 218 (or an RBG camera) configured to detect whether the cooling system 100 is operating using a clean condenser 102 or a partially clogged condenser 102. In this respect, as Figure 8A and Figure 8B As shown, a conventional camera device 218 can be configured to detect objects 802 of various sizes on the condenser 804. In one example, such as Figure 8A As shown, the camera device 218, together with the light source 800, can be used to detect larger objects / debris, such as, but not limited to, leaves, twigs, cardboard, cotton wool, etc. In another example, such as Figure 8B As shown, the camera device 218, together with the light source 800, can be used to detect small objects / debris 806 on the surface of the condenser 804, such as, but not limited to, dust, lint, etc.

[0064] As expected, Figure 8A As shown, monitoring of larger objects can be performed during the day or night. For example, camera device 218 can be configured to continuously check whether condenser 102 is blocked by any larger debris (e.g., leaves, cardboard, branches, etc.), wherein the general principles of object detection from image processing methods can be used by one or more controllers 202.

[0065] As expected, Figure 8B As shown, monitoring of smaller objects can be performed at night rather than during the day, reducing daytime light pollution and enabling accurate color estimation of a given object / surface. For example, camera device 218 can be configured to continuously monitor the RGB (red / green / blue) value differences of at least a portion of the surface of condenser 102. In such an example, if a black condenser is present, the "dirt" will change its color to a light gray spectrum.

[0066] Similarly, this paper anticipates that light reflection during nighttime can be monitored. For example, a clean condenser can have better light reflection compared to a clogged condenser, making poor light reflection an indication of condenser blockage.

[0067] This article anticipates that, as in Figure 8A and Figure 8B When using the common camera device shown, each of the previously discussed methods can be used individually or together to detect possible condenser fouling.

[0068] Refer again Figure 6The continuous monitoring method can utilize one or more pressure sensors 210. For example, as discussed earlier herein, baseline data can be collected after condenser cleaning or unit installation and compared with continuous monitoring data. It is anticipated that during continuous monitoring, the cooling system 100 can operate in a steady state within a given time frame. For example, the condenser fan speed and ambient air temperature may not change by more than 2% and 1K respectively over the past 5 minutes. If 10 consecutive assessments return an increase in the current differential pressure compared to the baseline, a warning signal regarding condenser fouling will be activated. The threshold can be a constant value, but it can also be a function of the condenser fan speed. Therefore, the threshold will have a lower value during lower speed (rpm) operation and a higher value during higher speed (rpm) operation.

[0069] Reference Figure 9 The continuous monitoring method may include a computation-based detection method 900 based on a mathematical model / algorithm to detect whether the cooling system 100 is operating with a clean condenser 102 or a partially blocked condenser 102. In a non-limiting example, the mathematical model / algorithm may be a mathematical model / algorithm for the compressor, condenser, and fan.

[0070] In step 902, it is determined whether the cooling system 100 is operating under a steady-state condition.

[0071] In step 904, the cooling capacity / heat to be removed is calculated. For example, the cooling / heating capacity can be calculated. For example, one or more processors 204 can be configured to use a mathematical model to calculate the cooling / heating capacity, such as how much heat / air the condenser should dissipate into the environment.

[0072] In step 906, the ambient air temperature can be measured.

[0073] In step 908, the fan speed ramp-up rate can be determined based on the measured ambient air temperature. For example, since we know the mathematical models of the condenser coil and fan and we have measurements of the environmental conditions, the expected condenser fan speed can be determined for a given heat load and environmental conditions.

[0074] In step 910, the current fan speed can be measured.

[0075] In step 912a, if the current fan speed in steady-state operation is higher than a first threshold, a message can be issued. In step 912b, if the current fan speed is higher than a second threshold, a warning can be issued. The second threshold may be higher than the first threshold. Then, in step 912c, method 900 further checks whether the current fan speed is higher than a third threshold, which is higher than the second threshold. If the answer is "yes" in step 912c, an alarm can be issued. Here, the message / warning / alarm for each step (e.g., steps 912a to 912c) can be different to differentiate between corresponding signals. An alarm generated based on a decision made in step 912c can be more significant (e.g., louder, brighter, etc.) than a warning generated based on a decision made in step 912b and / or a message generated based on a decision made in step 912a. For example, in a non-limiting example, a message generated by step 912a may indicate the lightest scaling, a warning generated by step 912b may indicate moderate scaling, and an alarm generated by step 912c may indicate high scaling that hinders normal operation. In this regard, messages can provide information about scaling, warnings can suggest cleaning, and alarms can indicate abnormal unit operation.

[0076] In step 914, if the current fan speed in steady-state operation is less than a given threshold, condenser fouling may not be detected (e.g., everything is normal).

[0077] Similarly, in the case of continuous differential pressure checks, to avoid introducing too much burden on the computational hardware, differential pressure checks can be performed at one or more predetermined intervals (e.g., every 1 minute). Furthermore, it is anticipated in this paper that the cooling unit must operate under steady-state conditions for proper evaluation. To check for steady-state conditions, we can check whether the ramp-up fluctuations of the compressor and condenser do not exceed 2% over the past 5 minutes, and whether the environmental changes are within 1 K. Other parameters to consider in the steady-state evaluation may be the suction pressure / temperature and the condensing pressure / temperature.

[0078] This paper anticipates that a similar approach can be used in the case of dry coolers, the only difference being the mathematical model, since the compressor's energy consumption and capacity are not related, but only the temperature difference between the inlet and outlet of the medium and its mass flow rate are related to the mathematical model.

[0079] Reference Figure 9 Continuous monitoring methods may include performing historical-based detection based on historical data to detect whether the cooling unit is operating with a clean condenser or a partially blocked condenser.

[0080] For example, during the lifespan of the cooling system 100, data can be collected and stored in memory. In a non-limiting example, the data may include, but is not limited to, heat dissipation, ambient air temperature and humidity, pressure differential, fan speed, images from a thermal imaging device, images from a conventional imaging device, red / blue / green (RBG) values, etc. Such data can be stored as a baseline and used to assess the cleanliness of the condenser. It is contemplated herein that the accumulated data can be used to compare data from the same / similar / different units. Furthermore, the accumulated data can be used to compare units in the same / similar / different geographical locations and / or units in the same / similar / different climates.

[0081] It is anticipated in this document that any combination of condenser detection methods may be used herein, unless otherwise stated herein.

[0082] Refer again Figure 2 This document notes that one or more components of system 200 can be communicatively coupled to various other components of system 200 in any manner known in the art. For example, one or more processors 204 can be communicatively coupled to each other and to other components via wired connections (e.g., copper wires, optical fibers, etc.) or wireless connections (e.g., RF coupling, IR coupling, WiMax, Bluetooth, 3G, 4G, 4G LTE, 5G, etc.). As another example, controller 202 can be communicatively coupled to one or more components of system 200 via any wired or wireless connection known in the art.

[0083] One or more processors 204 may include any or more processing elements known in the art. In this sense, one or more processors may include any microprocessor device configured to execute algorithms and / or program instructions. Generally, the term "processor" can be broadly defined as any device having one or more processing elements that execute a set of program instructions from a non-transitory storage medium (e.g., memory), wherein one or more sets of program instructions are configured to cause one or more processors to perform any of one or more process steps.

[0084] Memory 206 may include any storage medium known in the art suitable for storing one or more sets of program instructions executable by one or more associated processors. For example, the memory may include non-transitory storage media. For example, the memory may include, but is not limited to, read-only memory (ROM), random access memory (RAM), magnetic or optical storage devices (e.g., disks), magnetic tape, solid-state drives, etc. The memory may be configured to provide display information to a user device. Furthermore, the memory may be configured to store user input information from one or more user input devices. The memory may be housed together with one or more processors in a common controller housing. Alternatively or additionally, the memory may be located remotely relative to the spatial location of the processors and / or one or more controllers. For example, one or more processors and one or more controllers may access a remote database accessible via a network (e.g., the Internet, intranet, etc.) via one or more communication interfaces.

[0085] Note that one or more controllers can be installed in a common enclosure or externally. Therefore, Figure 2 This information is provided for illustrative purposes only and should not be construed as limiting the scope of this disclosure.

[0086] In a general sense, those skilled in the art will recognize that the various aspects described herein, which can be implemented individually and / or jointly by a wide range of hardware, software, firmware, or any combination thereof, can be considered as comprising various types of "electronic circuit systems." Therefore, as used herein, "electronic circuit system" includes, but is not limited to, electronic circuit systems having at least one discrete electronic circuit, electronic circuit systems having at least one integrated circuit, electronic circuit systems having at least one application-specific integrated circuit, electronic circuit systems forming general-purpose computing devices configured by computer programs (e.g., a general-purpose computer configured by a computer program that at least partially performs the processes and / or devices described herein, or a microprocessor configured by a computer program that at least partially performs the processes and / or devices described herein), electronic circuit systems forming memory devices (e.g., in the form of random access memory), and / or electronic circuit systems forming communication devices (e.g., modems, communication switches, or optoelectronic devices). Those skilled in the art will recognize that the subject matter described herein can be implemented in analog or digital modes, or some combination thereof.

[0087] The topics described herein sometimes illustrate different components contained within or connected to different other components. It should be understood that such architectures depicted are merely exemplary, and many other architectures can in fact achieve the same functionality. Conceptually, any arrangement of components that achieve the same function is effectively “associated” to achieve the desired function. Therefore, any two components combined herein to achieve a particular function can be considered “associated” with each other to achieve the desired function, regardless of the architecture or intermediate components. Similarly, any two components so associated can also be considered “operably connected” or “operably coupled” to each other to achieve the desired function, and any two components that can be so associated can also be considered “operably coupled” to each other to achieve the desired function. Specific examples of operably coupled components include, but are not limited to, physically matchable and / or physically interactable components and / or wirelessly interactable and / or logically interactable components.

[0088] While specific aspects of the subject matter described herein have been shown and described, it will be apparent to those skilled in the art that changes and modifications can be made based on the teachings herein without departing from the subject matter and its broader aspects, and therefore the appended claims are intended to cover within their scope all such changes and modifications that fall within the true spirit and scope of the subject matter described herein. Furthermore, it should be understood that the invention is defined by the appended claims.

Claims

1. A method for detecting condenser blockage in a cooling system, the method comprising: Determine the current state of the cooling system; Collect a set of measurement data, which includes at least one of pressure data, ambient air temperature data, condenser temperature data, humidity data, thermal image data, or image data from a conventional camera device; as well as The collected set of measurement data is analyzed to determine whether the condenser of the cooling system is at least partially blocked or clean.

2. The method according to claim 1, wherein, The analysis of the collected set of measurement data includes: Compare the set of measurement data with a predetermined threshold; and When the set of measurement data is determined to be greater than the predetermined threshold, a signal associated with at least partial blockage of the condenser is generated.

3. The method according to claim 2, wherein, Generating the signal associated with at least partial blockage of the condenser includes: Generate an alert.

4. The method according to claim 3, wherein, Generating the alert includes generating alerts of different levels based on the current state associated with the predetermined threshold. The alarm includes at least one of an audio alarm, a visual alarm, or a tactile alarm.

5. The method according to claim 1, wherein, The analysis of the collected set of measurement data includes: Compare the set of measurement data with a set of baseline data; and When the set of measurement data is determined to be greater than the set of baseline data, a signal is generated that is associated with at least partial blockage of the condenser.

6. The method according to claim 5, wherein, The set of baseline data includes historical data corresponding to the cooling system.

7. The method according to claim 1, wherein, The collected set of measurement data includes the thermal image data, which is captured by a thermal imaging device.

8. The method according to claim 7, wherein, The analysis of the collected set of measurement data includes: Identify clogging areas in the thermal image data; and Upon identifying the blockage area in the thermal image data, a signal is generated that is associated with at least partial blockage of the condenser.

9. The method according to claim 1, wherein, The collected set of measurement data includes image data from the ordinary camera device, wherein the image data from the ordinary camera device is captured by the ordinary camera device.

10. The method according to claim 9, wherein, The analysis of the collected set of measurement data includes: Determine the red / blue / green RGB values ​​of the image data from the ordinary camera device; The determined RBG value is compared with a predetermined RBG threshold; and When the RBG value is determined to be greater than the predetermined RBG threshold, a signal associated with at least partial blockage of the condenser is generated.

11. A cooling system, comprising: Condenser; Condenser fan; Evaporator; Evaporator fan; One or more continuous monitoring sensors are configured to continuously monitor the surface of the condenser; At least one of one or more temperature sensors, one or more pressure sensors, or one or more humidity sensors; as well as A controller communicatively coupled to at least the condenser, the one or more continuous monitoring sensors, and at least one of the one or more temperature sensors, the one or more pressure sensors, or the one or more humidity sensors, wherein the controller includes one or more processors, the one or more processors including a set of program instructions configured to cause the one or more processors to: Determine the current state of the cooling system; Collect a set of measurement data, said set of measurement data including at least one of the following: pressure data from one or more pressure sensors, ambient air temperature data from one or more temperature sensors, condenser temperature data, humidity data from one or more humidity sensors, thermal image data from one or more continuous monitoring sensors, or image data from a conventional camera device of one or more continuous monitoring sensors; and The collected set of measurement data is analyzed to determine whether the condenser of the cooling system is at least partially blocked or clean.

12. The cooling system according to claim 11, wherein, The analysis of the collected set of measurement data includes: Compare the set of measurement data with a predetermined threshold; and When the set of measurement data is determined to be greater than the predetermined threshold, a signal associated with at least partial blockage of the condenser is generated.

13. The cooling system according to claim 12, wherein, Generating the signal associated with at least partial blockage of the condenser includes: Generate an alert.

14. The cooling system according to claim 13, wherein, Generating the alert includes generating alerts of different levels based on the current state associated with the predetermined threshold. The alarm includes at least one of an audio alarm, a visual alarm, or a tactile alarm.

15. The cooling system according to claim 11, wherein, The analysis of the collected set of measurement data includes: Compare the set of measurement data with a set of baseline data; and When the set of measurement data is determined to be greater than the set of baseline data, a signal is generated that is associated with at least partial blockage of the condenser.

16. The cooling system according to claim 15, wherein, The set of baseline data includes historical data corresponding to the cooling system.

17. The cooling system according to claim 11, wherein, The one or more continuous monitoring sensors include a thermal imaging device, wherein a set of collected measurement data includes the thermal image data from the thermal imaging device.

18. The cooling system according to claim 17, wherein, The analysis of the collected set of measurement data includes: Identify clogging areas in the thermal image data; and Upon identifying the blockage area in the thermal image data, a signal is generated that is associated with at least partial blockage of the condenser.

19. The cooling system according to claim 11, in, The one or more continuous monitoring sensors include a conventional camera device, wherein the collected set of measurement data includes conventional camera device image data captured by the conventional camera device.

20. The cooling system according to claim 19, wherein, The analysis of the collected set of measurement data includes: Determine the red / blue / green RGB values ​​of the image data from the ordinary camera device; The determined RBG value is compared with a predetermined RBG threshold; and When the RBG value is determined to be greater than the predetermined RBG threshold, a signal associated with at least partial blockage of the condenser is generated.

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