HVAC Sensor Error Detection for Continuous Climate Control Operation

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Solution Overview

Problem

Traditional HVAC systems shut down when an error is detected in an ambient sensor, disrupting the supply of conditioned air to a space, which is undesirable as it interrupts climate control.

Innovation Solution

A control system that detects errors in ambient sensors and adjusts the operation of HVAC components, such as compressors and fans, to continue supplying conditioned air based on the type of HVAC unit and its mode of operation, ensuring continuous air supply even with sensor errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the HVAC system shuts down operation when an ambient sensor error is detected, then the system reliability is improved by preventing uncontrolled operation, but the climate control function is lost and occupant comfort is disrupted

Engineering Contradiction:
Improvesystem operation reliabilityVSAvoidclimate control continuity
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The control system dynamically adjusts its response based on the type of sensor error detected. For recoverable errors (temporary signal interruptions), the system maintains operation with fallback logic. For critical errors (permanent sensor failures), the system shuts down. This dynamic error-handling strategy resolves the contradiction by making the shutdown behavior conditional rather than absolute.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes its operational parameters based on error classification. When a non-critical error is detected, the system transitions from normal operation mode to fallback operation mode, where it continues running with modified control logic that doesn't rely on the faulty sensor. This parameter change allows the system to maintain climate control while still responding to sensor failures.

Inventive Principle:
Principle #35Parameter changes

2Ease of operation

If the HVAC system continues operation when an ambient sensor error is detected, then the climate control continuity is maintained, but the system may operate with incorrect parameters leading to potential damage or inefficiency

Engineering Contradiction:
Improveclimate control continuityVSAvoidsystem operation safety
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The system implements dynamic error assessment that distinguishes between temporary signal interruptions and permanent sensor failures. For temporary errors, the system continues operation with fallback logic. For permanent failures, it shuts down. This dynamic classification resolves the contradiction by making continuation conditional on the error type.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system converts the potentially harmful situation of operating with sensor errors into a beneficial outcome by classifying errors and applying appropriate responses. Non-critical errors become opportunities to demonstrate robust fallback operation, while critical errors trigger protective shutdowns. This transforms the error condition from purely harmful to potentially beneficial for system reliability.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If the HVAC system implements comprehensive error classification and conditional operation logic, then the system can maintain climate control during non-critical sensor errors, but the device complexity increases

Engineering Contradiction:
Improveclimate control continuityVSAvoidcontrol system complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The control system segments error handling into distinct categories (critical vs. non-critical errors) with dedicated response logic for each. This segmentation allows the system to implement complex error classification without creating a monolithic control structure, making the complexity manageable and maintainable while achieving continuous climate control during non-critical errors.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS10712033B2Control of HVAC unit based on sensor status
Publication Date: 2020.07.14 JOHNSON CONTROLS LIGHT COMMERCIAL IP GMBH
  • US10712033B2 patent drawing
  • US10712033B2 patent drawing
  • US10712033B2 patent drawing

AI summary

The present disclosure is directed to a system for a heating, ventilating, and air conditioning (HVAC) system includes a compressor configured to circulate a working fluid through the HVAC system, a fan configured to direct across a heat exchanger coil of the HVAC system, an ambient sensor configured to monitor a condition of an environment surrounding the heat exchanger coil, and a control system communicatively coupled to the ambient sensor, where the control system is configured to detect a status of the ambient sensor, and where the control system is configured to adjust operation of the compressor, or the fan, or both, upon detection of an error of the ambient sensor.