Energy saving controller

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Solution Overview

Problem

Conventional HVAC systems waste energy as the fan stops blowing before residual heat or cooling energy is fully utilized, and malfunctioning thermostats can cause unknown voltage states, leading to continuous fan operation or system shutdown.

Innovation Solution

A plug-and-play energy saving controller (ESC) is inserted between the thermostat and air handler, using a microprocessor and triacs to extend fan run time based on residual energy and thermostat signal processing, converting unknown voltage states to known states to ensure proper system operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the fan stops blowing after the heating or cooling unit shuts off, then energy consumption is reduced, but residual heat or cooling energy is wasted

Engineering Contradiction:

Improveresidual heat or cooling energyVSAvoidfan energy consumption

Core Design Contradiction:

Loss of energyVSUse of energy by moving object

Solution Approach 1:

The controller predicts the residual energy in the heating or cooling unit before the fan stops, and extends the fan run time in advance to utilize this residual energy, thereby converting what would be wasted energy into useful cooling or heating effect

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The controller monitors the operating status and residual energy of the heating or cooling unit, and adjusts the fan run time based on this feedback information to optimize energy utilization

Inventive Principle:

Principle #23Feedback

2Reliability

If the thermostat output signal is in unknown voltage state, then the system cannot properly detect the off state, but extending fan run time consumes additional energy

Engineering Contradiction:

Improvethermostat signal detectionVSAvoidfan energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The controller acts as an intermediary between the thermostat and the fan, detecting the thermostat's output signal and converting unknown voltage states into known states, thereby enabling reliable detection of the off state without unnecessary fan operation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the compressor or heater runs continuously for long periods, then cooling or heating demand is met, but equipment lifespan is reduced due to excessive temperature

Engineering Contradiction:

Improveequipment lifespanVSAvoidcooling or heating output

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The controller implements periodic shutdown of the compressor or heater after continuous operation for a predetermined period, allowing the equipment to rest and cool down, thereby extending lifespan while maintaining overall cooling or heating effectiveness through cyclical operation

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS10808961B2Energy saving controller

Publication Date: 2020.10.20 LAU JAMES LEYCH

AI summary

A method for controlling an air handler including a fan, a heater and/or a compressor, by installing an energy saving controller between a thermostat and the air handler, shutting down the compressor or heater for a first predetermined duration if the compressor or heater has run continuously for a second predetermined duration during the current cycle, while allowing the fan to run for a fan's first run time extension amount equal with the first predetermined duration.