Air Filter Remaining Life Prediction Using Optical Sensing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current air filter maintenance schedules often result in filters being changed too frequently or not soon enough, leading to increased costs and complexity, as well as potential negative impacts on product lifetime due to inadequate or excessive filter replacement intervals.

Innovation Solution

A system and method for predicting the remaining life of air filters by transmitting light towards the filter, measuring the reflected light, and using a database to determine the filter's remaining life based on slope analysis and periodic measurement updates, with features including alarm and warning limits, user input, and logging of filter changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If air filters are changed on set intervals, then maintenance scheduling is simplified, but filters may be changed too frequently or not soon enough, increasing costs and complexity

Engineering Contradiction:

Improvemaintenance schedulingVSAvoidfilter replacement timing

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces mechanical/time-based filter change scheduling with an optical sensing system that uses light transmission measurements to determine filter condition. A light source transmits light through the filter and a sensor measures the transmitted light, converting physical filter degradation into measurable optical signals for automated assessment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements continuous feedback by periodically measuring light transmission through the filter and comparing it against baseline values. When the measured transmission falls below threshold values indicating significant debris accumulation, the system triggers maintenance alerts, creating a closed-loop feedback mechanism that adapts to actual filter condition rather than following fixed schedules.

Inventive Principle:

Principle #23Feedback

2Reliability

If filters are changed more frequently, then product lifetime is extended, but maintenance costs and complexity increase

Engineering Contradiction:

Improveproduct lifetimeVSAvoidmaintenance costs

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system transitions from static, predetermined maintenance intervals to dynamic, condition-based maintenance scheduling. The measurement frequency and maintenance triggers are adjusted based on actual filter degradation rates detected through optical measurements, allowing the system to adapt maintenance timing to real-time filter condition rather than following rigid schedules.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the parameter used for maintenance scheduling from time-based intervals to condition-based parameters measured through light transmission. By monitoring the optical properties of the filter (light transmission intensity, spectral characteristics), the system identifies the actual functional state of the filter and schedules maintenance based on physical degradation rather than elapsed time.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If light transmission measurements are taken frequently, then remaining life prediction accuracy is improved, but measurement and data processing complexity increases

Engineering Contradiction:

Improveremaining life prediction accuracyVSAvoidmeasurement and data processing

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system applies partial measurement action by taking light transmission measurements at strategically selected intervals rather than continuously. The control system determines when measurements are necessary based on operational conditions and trends, performing measurements only when needed to update the remaining life prediction, thus reducing overall measurement frequency while maintaining prediction accuracy.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system performs preliminary baseline measurements when the filter is new and establishes reference light transmission values. These preliminary measurements create a baseline against which subsequent measurements are compared, allowing the system to predict remaining life based on deviation from the baseline rather than requiring continuous absolute measurements, thereby simplifying ongoing data processing.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables more accurate and timely filter replacement scheduling, reducing unnecessary maintenance costs and extending product lifetime by providing precise predictions of filter life expectancy and facilitating proactive maintenance planning.

Implementation Method 1

transmitting light toward the filter, taking a measurement of light reflected from the filter

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20240402077A1Air filter remaining life prediction

Publication Date: 2024.12.05 VERTIV CORP

AI summary

A method of predicting a remaining life of a filter can include transmitting light toward the filter, taking a measurement of light reflected from the filter, adding the measurement to a database, predicting the remaining life of the filter using the database, displaying the remaining life of the filter, or any combination thereof. The light can include infrared light.