HVAC Control Board Fault Detection Using Substitute Sensor Data
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Solution Overview
Problem
HVAC systems face operational challenges and reduced lifespan due to faults in sensors, leading to inefficient operation and potential damage when continuing to operate with faulty components.
Innovation Solution
A control board and method that detect faulty sensors in HVAC systems, allowing substitution of sensor information from alternative sources, such as temperature sensors or variable speed drive data, to maintain system functionality and reduce operational risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the HVAC system continues to operate with a faulty sensor, then productivity is maintained, but reliability deteriorates due to potential system damage and reduced lifespan
Solution Approach 1:
The control board performs preliminary detection of sensor faults and activates substitute sensor data before the faulty sensor causes system damage. By detecting the fault condition and switching to alternative data sources in advance, the system maintains operation while preventing the faulty sensor from causing harm
Solution Approach 2:
Substitute sensor data acts as an intermediary between the faulty sensor and the control system. When the primary sensor fails, the control board uses data from alternative sensors (such as using temperature sensors to infer pressure conditions) to maintain system control without directly relying on the faulty component
2Reliability
If the HVAC system shuts down when a sensor fault is detected, then reliability is maintained, but productivity deteriorates due to loss of cooling or heating functionality
Solution Approach 1:
The HVAC system performs self-service by automatically detecting sensor faults and switching to substitute data sources without requiring external intervention or shutdown. The control board monitors sensor health and autonomously transitions to alternative measurement methods, allowing the system to service itself and maintain operation
Solution Approach 2:
The control board changes the parameter source from the faulty sensor to alternative sensors based on the fault condition. For example, it may switch from direct pressure sensor readings to temperature-based pressure calculations, changing how the system obtains critical operational parameters while maintaining functionality
3Productivity
If substitute sensor data is used to maintain operation, then productivity is maintained, but measurement precision deteriorates compared to using the original sensor data
Solution Approach 1:
The control board implements feedback by continuously monitoring the quality and consistency of substitute sensor data. When the substitute data indicates deteriorating conditions or becomes unreliable, the system can adjust control strategies or alert operators, ensuring that productivity is maintained only while measurement precision remains acceptable
Data Source
AI summary
The present disclosure includes techniques that enable a conditioned air system to automatically restore functionality and/or to operate at reduced functionality when a fault is detected, for example, to facilitate reducing likelihood that continuing operation with the fault present will decrease lifespan of the conditioned air system. To facilitate improving operation of the conditioned air system when a fault is present, the control system of the conditioned air system may utilize substitute sensor data and/or adjust its control algorithm. In this manner, the control system may facilitate improving operational reliability and/or availability of the conditioned air system, for example, by adaptively adjusting its operation to enable the conditioned air system to continue operating even when a fault is present, while reducing likelihood that the continued operation will reduce lifespan of the conditioned air system.