Modular HVAC Controller for Reduced Compressor Cycling
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Solution Overview
Problem
Existing small-scale HVAC systems face challenges in achieving flexibility and energy efficiency due to the limitations of discrete controllers, which are either custom-built for specific applications or lack the compactness and modularity needed for various environments, leading to increased energy consumption from frequent compressor startups and stops.
Innovation Solution
A discrete core controller with modular capabilities that utilizes a learning algorithm and distributed intelligence to reduce compressor cycling, allowing for flexible configuration across different applications, and includes a master control unit that dynamically adjusts compressor and fan speeds to minimize energy usage and extend equipment lifespan through load balancing across multiple units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete controllers are custom-built for specific applications, then application-specific performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent implements a universal controller platform that can be configured for multiple HVAC applications through software programming rather than hardware customization. The controller includes programmable function blocks for various control strategies (on/off, proportional, integral, differential, predictive) and can adapt to different applications (residential, commercial, industrial) through configuration settings, eliminating the need for custom-built controllers for each application.
Solution Approach 2:
The controller architecture is divided into modular functional blocks that can be independently programmed and configured. These include separate function blocks for temperature control, humidity control, energy management, and system monitoring, allowing flexible combination and configuration for different applications without redesigning the entire system.
2Adaptability or versatility
If modular controllers are used for flexibility, then adaptability across applications is improved, but device compactness and cost worsen
Solution Approach 1:
The patent merges multiple control functions (temperature control, humidity control, energy management, system monitoring) into a single integrated controller unit. This consolidation provides the flexibility of modular systems while maintaining the compactness of a discrete controller, as all functions share common hardware resources including processor, memory, and I/O interfaces.
3Ease of operation
If high gain on/off control is used in residential HVAC, then control simplicity is improved, but energy consumption increases due to frequent compressor cycling
Solution Approach 1:
The controller dynamically adjusts control parameters based on system conditions. It transitions between different control modes (on/off, proportional, predictive) and adjusts setpoints and hysteresis bands in real-time based on outdoor temperature, humidity, and system performance data, optimizing energy consumption while maintaining comfort.
Solution Approach 2:
The controller uses predictive function blocks that pre-calculate optimal control actions based on forecasted weather conditions and thermal load patterns. This allows the system to prepare ahead of time, reducing unnecessary compressor cycles by anticipating temperature changes and adjusting pre-cooling or pre-heating strategies accordingly.
4Use of energy by moving object
If compressor cycling is reduced through advanced control, then energy consumption is improved, but control system complexity increases
Solution Approach 1:
The controller implements multiple feedback loops that monitor system performance, outdoor conditions, and energy consumption. The feedback data is used to continuously optimize control parameters and adjust control strategies, reducing compressor cycling while maintaining simple operation for the end user through automated decision-making algorithms.
Data Source
AI summary
A universal controller for control of air handling and HVAC equipment. The base controller includes a fixed task portion as well as a modular portion for expansion of control features with modules. The fixed task portion is suitable for enclosure or cabinet control. The modular portion enables expansion from basic cabinet control to more complex control schemes. In one embodiment, the base controller is provided in a kit including appurtenances such as variable speed drives that enable proportional-type control of a residential air conditioning system. In another embodiment, a plurality of modules are ganged together in a rotating master/slave arrangement to distribute wear on the respective controlled air conditioning equipment.