Provisioning wireless mesh networks for heating, ventilation, and air conditioning systems
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Solution Overview
Problem
Configuring a large number of roof-top units (RTUs) in HVAC systems to form a mesh network is time-consuming and inefficient, leading to delays and downtime, as existing methods require individual connection to each unit and are affected by the physical distribution and communication range of RTUs, resulting in degraded network performance with increased size.
Innovation Solution
A system where controllers act as temporary gateways to configure a subset of controllers to form a mesh network, using peer-to-peer connections and network credentials to join either an existing or new mesh network based on signal strength, reducing setup time and improving throughput by optimizing connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual connection method is used to configure each RTU, then each controller can be configured to form a mesh network, but the setup time increases significantly as the number of RTUs increases
Solution Approach 1:
The patent uses a portable computing device as an intermediary to configure multiple controllers simultaneously. Instead of connecting to each controller individually, the portable device acts as a central mediator that can establish connections with multiple controllers in sequence or parallel, retrieving and distributing mesh network configuration data efficiently. This intermediary approach dramatically reduces setup time while maintaining proper mesh network formation.
Solution Approach 2:
The system performs preliminary actions by pre-configuring mesh network parameters and credentials on the portable computing device before approaching the controllers. The portable device stores network security credentials, encryption keys, and mesh topology information in advance, allowing for rapid deployment to multiple controllers without requiring individual configuration sessions for each parameter.
2Area of stationary object
If controllers are distributed throughout a worksite, then coverage is improved, but communication range limitations prevent some controllers from communicating with all other devices
Solution Approach 1:
The patent implements mesh network segmentation where the overall network is divided into multiple sub-networks or clusters. Controllers are organized into groups that can communicate reliably within each cluster, while gateway controllers bridge between clusters. This segmentation allows wide geographic coverage while maintaining reliable communication within each segment, solving the problem of controllers being out of range of distant devices.
Solution Approach 2:
The system transitions from a flat, single-layer mesh topology to a multi-dimensional hierarchical structure. Instead of requiring direct peer-to-peer communication between all controllers, the patent introduces intermediate gateway controllers and multiple communication hops. This dimensional change in network topology allows controllers to reach distant devices through intermediate nodes, extending effective communication range while maintaining reliability.
3Quantity of substance
If the mesh network size increases to accommodate more RTUs, then more devices can be controlled, but network performance degrades due to increased number of hops
Solution Approach 1:
The patent divides the large mesh network into multiple smaller logical segments or virtual networks. Each segment maintains a limited number of hops for optimal performance, while segmentation allows the overall system to scale to accommodate hundreds or thousands of controllers. Data transmission speed is preserved within each segment, and inter-segment communication occurs through designated gateway nodes.
Solution Approach 2:
The portable computing device serves as a configuration intermediary that optimizes mesh network topology during setup. It analyzes the physical layout and controller locations to create an efficient network structure that minimizes average hop counts. The device can also act as a temporary communication intermediary during the provisioning process, allowing configuration data to be distributed efficiently without requiring full mesh path establishment for each controller.
4Area of stationary object
If controllers are configured to form a large mesh network, then system coverage is expanded, but the complexity of configuring and maintaining the network increases
Solution Approach 1:
The patent implements self-service mechanisms where controllers automatically retrieve their configuration parameters from the portable computing device without requiring manual intervention. The portable device automatically generates unique identifiers, security credentials, and routing information for each controller based on its position in the mesh network. This automation dramatically reduces configuration complexity while enabling large-scale network deployment.
Solution Approach 2:
The system performs preliminary network design and configuration planning using the portable computing device before actual controller deployment. The portable device stores pre-calculated mesh topology, security credentials, and communication parameters that will be automatically distributed to controllers. This preliminary action reduces on-site configuration complexity and allows rapid deployment of large networks with minimal technical expertise required during installation.
Data Source
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AI summary
A system (100) that includes a plurality of controllers (108) that are each controller is configured to operate at least a portion of a Heating, Ventilation, and Air Conditioning (HVAC) system (104). The plurality of controllers (108) are members of an unprovisioned mesh network (110). The system (100) further includes a network provisioning device (102) that is configured to establish a peer-to-peer connection with the controller (108). The device is further configured send a request to the controller (108) to identify a wireless network that is in range of one or more controllers that are members of the unprovisioned mesh network and to obtain network credentials for the identified wireless network. The network device (102) is further configured to send the network credentials to the controller (108) to join a provisioned mesh network (112). The controller (108) is configured to propagate the network credentials to other controllers (108) within the unprovisioned mesh network (110).