WO2016064780A1 - Procédé de régulation de la demande d'équipement de chauffage, de ventilation, de climatisation et de réfrigération (cvc et r) à cycle de service et dispositifs de commande et systèmes pour celui-ci - Google Patents
Procédé de régulation de la demande d'équipement de chauffage, de ventilation, de climatisation et de réfrigération (cvc et r) à cycle de service et dispositifs de commande et systèmes pour celui-ci Download PDFInfo
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- WO2016064780A1 WO2016064780A1 PCT/US2015/056307 US2015056307W WO2016064780A1 WO 2016064780 A1 WO2016064780 A1 WO 2016064780A1 US 2015056307 W US2015056307 W US 2015056307W WO 2016064780 A1 WO2016064780 A1 WO 2016064780A1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/30—Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/30—Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring
- F24F11/46—Improving electric energy efficiency or saving
- F24F11/47—Responding to energy costs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/50—Control or safety arrangements characterised by user interfaces or communication
- F24F11/56—Remote control
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
- F24F11/63—Electronic processing
- F24F11/64—Electronic processing using pre-stored data
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/70—Control systems characterised by their outputs; Constructional details thereof
- F24F11/80—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air
- F24F11/83—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling the supply of heat-exchange fluids to heat-exchangers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F11/00—Control or safety arrangements
- F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
- F24F11/63—Electronic processing
Definitions
- the present invention relates to a method for automatic demand control of duty cycled, electrical energy-consuming heating, ventilating, air conditioning and/or refrigeration equipment, including compressor and/or gas-, oil-, and propane-fired heating equipment with or without blowers controlled via electrically powered control systems.
- the present invention also relates to an electronic controller for implementing such methods and heating, ventilating, air conditioning, and refrigeration equipment systems incorporating such an electronic controller.
- One charge is based on total consumption of electricity during a billing cycle, usually one month, and another charge is the peak demand, which is based on the highest capacity or peak intensity required by the customer during that same billing cycle. Since commercial and industrial users can have significant variance in both consumption and demand, these charges are often broken out for them as part of their rate structure.
- Total consumption for a billing cycle is measured in kWh, and demand is measured in kilowatts (kW).
- the consumption component of the customer's energy bill can be calculated by multiplying the utility's consumption rate (price per kWh) times the kWh of the customer's consumption during the billing cycle.
- Electrical demand is the maximum flow of electricity used at any one time by a customer measured in kilowatts (kW).
- Peak Demand is the largest value of kW used during the billing cycle, which typically is measured and averaged over a 15 minute moving window interval that "slides” through the entire month (billing cycle). That is, this 15-minute interval typically is monitored as a "moving" window which can encompass any 15 minute block of time within the billing period. Peak demand typically is reset to 0 at the start of each month (billing period).
- the utility's demand charge is a fee rate (e.g., cost/kW).
- Demand charge for customers in the Northern Hemisphere for example, generally can be lower in the winter months (November to April) and higher in the summer months (May - October). The demand charge can be used by the utility to pay for the overhead cost of providing the electrical generating equipment to meet demand.
- Demand charge often applies to commercial, industrial, and agricultural customers, and usually not to residential customers (unless, for example, it is shared for a service area).
- the demand charge is calculated as the product of the utility's demand charge rate (cost/kW) times the peak demand (kW) for the billing cycle.
- the calculated charges for the consumption component and demand component for a billing cycle are combined in the customer's energy bill for the billing period.
- peak demand charges can represent a significant portion of the utility bill.
- Some commercial and industrial energy users for example, need large amounts of electricity only intermittently, seasonally, or occasionally, while others almost constantly.
- Large scale HVAC&R systems such as used in large commercial buildings, building complexes, and industries, or other large environmentally-controlled structures, can experience much higher peaks in demand, such during severe temperatures in weather conditions and during start-up of energy-intensive equipment used in the systems, making it even more imperative to find ways to reduce demand charges.
- HVAC&R Heating, ventilating, air conditioning and/or refrigeration
- Compressors and blowers used in these systems typically operate with electrically-powered motors.
- Increased focus on carbon footprint and green technologies has led to numerous energy related improvements, including more efficient refrigerants, variable speed compressors and fans, cycle modifications, and more efficient burners.
- electrical energy costs continue to increase in many markets and energy conservation becomes increasingly important, a need remains for innovations that can be applied to HVAC&R equipment in new as well as existing systems that can assist energy users in curtailing their energy demand usage and costs associated therewith.
- a feature of the present invention is to provide a method to automatically manage and provide demand control of duty cycled HVAC&R equipment in an improved manner as compared to operation with thermostat control itself.
- a further feature of the present invention is to provide an electronic controller which can be used as an add-on device in HVAC&R systems with thermostat control which automatically manages and provide demand control of duty cycled HVAC&R equipment.
- Another feature of the present invention is to provide systems which incorporate the indicated controller to automatically manage and provide demand control of duty cycled HVAC&R equipment in the system.
- the present invention relates to a method for demand control of at least one duty cycled HVAC/R equipment powered by electricity with limiting of equipment unit starts per time interval, comprising: a) intercepting a thermostat command signal in-route to at least one HVAC/R load unit and determining a pulsed command signal which comprises alternating pulse on and pulse off cycles which have respective durations that are determined according to demand regulator computations comprising steps i)-iv), which comprise: i) inputting maximum equipment starts per hour, short cycle time, and demand setpoint, and initializing pulse off-time to the short cycle time, ii) calculating pulse on-time needed to meet the demand setpoint and the pulse off-time, iii) calculating number of starts per hour and pulse off-time, iv) calculating excess starts per hour, wherein if the calculated value of excess starts per hour is greater than zero, then pulse off-time is increased and the increased pulse
- the present invention further relates to an electronic controller device for demand control of a duty cycled HVAC/R equipment with limiting of equipment starts per time interval, comprising: at least one input connector for attaching at least one thermostat signal line and at least one output connector for attaching at least one signal line for outputting a control signal from the controller device to a load unit, wherein the controller device intercepts a thermostat command signal in-route to the load unit and replaces the thermostat command signal with a pulsed command signal that is transmitted to the load unit for automatically controlling the load unit while the thermostat command signal is calling for heating, cooling or refrigeration duty by the load unit, wherein the pulsed command signal comprises alternating pulse on and pulse off cycles which have respective durations that are determined according to demand regulator computations that are performed with at least one processor and at least one memory storing instructions, the instructions comprising one or more instructions which, when executed by the at least one processor, cause the at least one processor to execute steps comprising steps i)-iv), which comprise i) inputting maximum equipment starts per hour, short cycle time, and demand
- the present invention further relates to an electronic controller device for demand control of a duty cycled HVAC/R equipment with limiting of equipment starts per time interval, comprising: at least one input connector for attaching at least one thermostat signal line and at least one output connector for attaching at least one signal line for outputting a control signal from the controller device to a load unit, wherein the controller device intercepts a thermostat command signal in-route to the load unit and replaces the thermostat command signal with a pulsed command signal that is transmitted to the load unit for automatically controlling the load unit while the thermostat command signal is calling for heating, cooling or refrigeration duty by the load unit, wherein the pulsed command signal comprises alternating pulse on and pulse off cycles which have respective durations that are determined according to demand regulator computations that are performed with at least one processor and at least one memory storing instructions, the instructions comprising one or more instructions which, when executed by the at least one processor, cause the at least one processor to execute steps comprising the indicated steps i)- iv) or l)-4).
- HVAC&R heating, ventilating, air conditioning or refrigeration
- FIG. 1 is a block/schematic diagram of a HVAC&R system including an electronic controller according to an example of the present invention.
- FIG. 2 is a block diagram of a microcontroller of the electronic controller of FIG. 1 according to an example of the present invention.
- FIG. 3 is a graph that shows demand regulator behavior with respect to the controller off times and on times, and conditioned space (zone) temperature (°F) over a period time for a simulated control of a load device in a cooling application of a HVAC&R system controlled with an electronic controller according to an example of the present invention with the inventive controller on/off signal times indicated as "Pace” and the on/off times of the original equipment manufacturer thermostat indicated as "OEM.”
- FIG. 4A is a flow chart of process control logic of a process using the electronic controller for automatically controlling operation of a FfVAC&R system according to an example of the present invention.
- FIG. 4B is a glossary table for block elements shown in FIG. 4A, according to an example of the present invention.
- FIG. 5 is an electrical connection diagram for a single stage cooling application using the electronic controller according to an example of the present invention, wherein this configuration is shown as used when a single thermostat is used to control one FTVAC cooling device (e.g., a compressor).
- FTVAC cooling device e.g., a compressor
- FIG. 6A is a plot showing the demand with respect to demand set point (D*) ("Demand Command, fraction” indicated by “o” trace lines) and actual demand ("Demand Response, fraction” indicated by “x” trace lines) over a period time for the simulated control indicated for FIG. 5 of the load device of a HVAC&R system with the electronic controller according to an example of the present invention with a maximum equipment starts per hour (nkMax) of 4.
- D* Demand Set point
- nkMax maximum equipment starts per hour
- FIG. 6B is an enlarged view of a portion of the plot showing the demand with respect to demand set point (D*) ("Demand Command, fraction” indicated by “o” trace lines) and actual demand (“Demand Response, fraction” indicated by “x” trace lines) of the plot of FIG. 6 A for the time range of 39100 to 40900 seconds, according to an example of the present invention.
- FIG. 7 is a plot showing the on time (tOn) ("o" trace lines) and off time (tOff) ("x" trace lines) behavior over a period time for the simulated control shown in FIG 6A.
- FIG. 8 is a plot showing the equipment starts per hour (nk) performance over a period of time for the simulated control shown in FIG. 6A.
- FIG. 9 is a plot showing the demand with respect to demand set point (D*) ("Demand Command, fraction” indicated by “o” trace lines) and actual demand ("Demand Response, fraction” indicated by “x” trace lines) over a period time for the simulated control indicated for FIG. 5 of the load device of a FfVAC&R system with the electronic controller according to an example of the present invention with a maximum equipment starts per hour (nkMax) of 4 at time 0 to 40,000 seconds, a maximum equipment starts per hour (nkMax) of 8 for the time period 40,000 to 60,000 seconds, and a maximum equipment starts per hour (nkMax) of 4 at time 60,000 seconds onward.
- D* Demand Command, fraction
- x Actual demand
- FIG. 10 is a plot showing the on time (tOn) ("o" trace lines) and off time (tOff) ("x" trace lines) behavior over a period time for the simulated control of the load device of a HVAC&R system shown in FIG. 9.
- FIG. 11 is a plot showing the equipment starts per hour (nk) performance over a period of time for the simulated control shown in FIG. 9.
- the present invention relates in part to staged and on/off heating, cooling, and refrigeration equipment under closed loop temperature and/or humidity control via hysteresis thermostat.
- electrical demand consumption can be controlled by exercising duty cycle control on an on/off system.
- the present invention in part relates to providing and using a demand regulator controller that uses original equipment manufacturer (OEM) subcycle pulsing to create a replacement control signal duty cycle which maintains a specified (e.g., preselected) electrical demand level in the equipment.
- An algorithm of the demand regulator controller of the present invention can constrain the on times and off times that the controller device sends to a load unit to meet a number of starts that reduces load unit demand while avoiding short cycling of the load unit.
- the indicated demand regulator controller can be implemented as part of a retrofittable electronic controller add-on device that includes integrated programs that can automatically and optimally calculate and control execution of duty cycles and cycle time durations for heating equipment, cooling equipment, and/or refrigeration equipment that are controlled using duty cycling to maintains a specified electrical demand level.
- the add-on electronic controller device can be installed in series in one or more thermostat control signal lines, which is capable of intercepting thermostat signals before they reach an intended load unit of an HVAC&R system.
- the electronic controller device can apply an algorithm to OEM signals and behavior thereof to generate an output signal for the load unit that can replace (or allow) the original control signal, to maintains a specified electrical demand level in the system.
- the electronic controller device includes at least a demand regulator (DR) controller.
- DR demand regulator
- the demand regulator controller can be implemented as a computer program stored in memory and executable with a microprocessor embodied by the electronic controller device.
- the program can provide a signal processing algorithm.
- the electronic controller device can include signal generation capability to output control signals from the controller device to the load unit.
- the electronic controller device can be readily retrofitted into an existing HVAC&R system, or incorporated into a new HVAC&R system.
- the electronic controller device does not need direct sensor support or line power to function as designed.
- the electronic controller device of the present invention can improve demand management.
- the demand regulator controller included in the electronic controller device can prevent the load unit from running continuously to meet demand.
- the demand regulator controller can periodically turn off the load unit, which may tend to increase the time period needed to provide a temperature adjustment back to the set point but provide a net reduction in the overall demand needed. This can be important because, as indicated, the cost of electricity, in commercial and industrial applications, is based on two items; (1) the total kW consumption and (2) the peak kW demand.
- the total kW consumption is (ideally) proportional to the equipment runtime.
- the peak kW demand is the largest average value of the kW consumption in a 15 minute (or 30 minute, etc.) interval or window during the billing cycle.
- the peak kW demand value is used to determine how electricity charges are established, wherein demand cost is the product of the demand charge (cost/kW) multiplied by the peak demand (in kW) for the billing cycle. Further, electricity is charged in different "declining block rates" of kWh, each of which has a kWh cost associated with it. The first block (the one filled first) is the most expensive; the second block (the one filled next) is less expensive, and so on. Given a constant total kW consumption, the total cost of electricity can be varied by the Peak kW demand value, the smaller the value of the Peak kW demand is made, the lower the cost.
- the indicated demand control regulator of the electronic controller device of the present invention can be used to lower the value of Peak kW demand.
- the demand regulator controller can reduce the worst case demand while still providing adequate cooling or heating of conditioned space as applicable with the controlled load unit.
- peak demand for the load unit can be reduced at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 50%, or from 10% to 50%, or from 10% to 40%, or from 15% to 35%, or other amounts, as compared to operation of the load unit with the thermostat command signals (e.g., the OEM thermostat signals) over the same time period.
- the thermostat command signals e.g., the OEM thermostat signals
- FIG. 1 shows a HVAC&R system 11 including an electronic controller device 18 on which the indicated demand regulator controller program or programs can reside and from which the program can be executed for signal processing and generation.
- the electronic controller 18 can be retrofitted in the system 11 to provide control of at least one HVAC&R load unit 20 that provides condition control in a zone 2.
- Power line 10 passes through utility meter 12 at the structure where at least one load unit 20 to be controlled is located.
- Meter 12 measures usage and demand of electrical energy at that location.
- Load unit 20 can be, for example, an air conditioner, heat pump, furnace, refrigerator, boiler, or other load unit of a HVAC&R system.
- Operative main power line 10 generally is unconditioned, and supplies operative power to load unit 20 via load control switch 26, such as a relay, and typically other load units and appliances in the same structure (not shown).
- the power supply line 10 can be, for example, a 110 volts alternating current (VAC), or 220 VAC, or other mains power supply line powering the HVAC&R system 11 to be retrofit with the controller 18.
- the system 11 to be retrofit has at least one standard thermostat 14 connected to the HVAC&R load unit 20.
- Thermostat 14 can be connected via line 13 to power line 10.
- a step-down transformer such as 24 volt transformer, which may be used in powering the thermostat from power line 10, is not illustrated in this figure, but is illustrated in the wiring diagram shown in FIG. 5.
- Electronic controller device 18 is not directly powered from power line 10, and it does not need to be. Electronic controller device 18 is powered by the thermostat signaling intended for the load device(s). The electronic controller device 18 typically is electrically dormant (or inactive) or sleeps with respect to its signal processing features until receiving/intercepting an ON signal from the thermostat, and then controller device 18 becomes awakened (active) to apply a program as part of an algorithm such as shown herein for signal control processing and control signal generation to the intended load device(s).
- a control signal line 15 of thermostat 14 can transmit an AC voltage of 24 volts during the periods when a thermostatic control is, for example, calling for cooling from an air conditioning unit (load unit), or heating from an electric furnace, and so forth.
- the control signal would normally activate load control switch 26 in main power line 10 to power the load unit 20. That is, in the absence of electronic controller device 18, control signal line 15 would be in control of opening or closing load unit control switch 26, and thereby opening or closing the circuit of operative power line 10 and controlling the flow of operative power to load unit 20.
- the electronic controller device 18 is interposed and installed in the thermostat control signal line 15 in series at some point between thermostat 14 and the load unit control switch 26. As shown, thermostat line 15 can be cut and connected at one cut end to electronic controller device 18. As also shown, the remaining portion of the cut signal control line, referenced as line 24, can be connected at one end to electronic controller devicel8 and at the other end to load control switch 26.
- the electronic controller device 18 can be physically mounted, for example, in sheet metal (not shown) near the load unit 20, such as a standard sheet metal construction enclosure used with the load unit.
- this tapping of controller device 18 into the control signal line 15 (24) is made as close as practically feasible to the load control switch 26.
- the connection of electronic controller device 18 in the control signal line could be made, for example, within the casing containing the compressor unit of a residential air conditioning unit.
- the electronic controller device 18 could be mounted in a sheet metal enclosure that houses the OEM controls for a compressor of an air conditioning unit as installed on a slab or platform near ground level immediately adjoining a home or building supported by the unit, or on a rooftop thereof.
- Electronic controller device 18 can include on-board user interface controls 19 and/or can receive control inputs and/or parameter data 23 from a remote input device 21, which can be further understood by other descriptions herein that will follow.
- the input device 21 can be "remote" in the sense that it is a physically separate device from electronic controller device 18, which can communicate with the controller, such as via an attachable/detachable communication wire or cable link or a wireless communication link.
- electronic controller device 18 receives electrical flow over control signal line 15 based on a thermostat control signal intended for powering up the load unit 20, and electronic controller device 18 can immediately awaken to intercept the thermostat signal and initiate its suite of control programs before an output control signal is sent from the electronic controller device 18 to the load unit switch 26.
- the output control signal may be a replacement signal for the OEM signal or the OEM signal, depending on the outcome of the running of the controller's algorithm.
- the thermostat 14 preferably is (pre)configured to generate only an ON/OFF signal, by which the air conditioner/heat pump compressor, furnace, or other load unit is turned on/off.
- the thermostat 14 used in the system 11 is designed to provide ON/OFF control at a load unit to turn the load unit completely on or completely off.
- the thermostat can decide if the output needs to be turned on, turned off, or left in its present state.
- ON/OFF control by an OEM thermostat typically comprises selecting a set point, and a native or default OEM deadband may apply or may be selected by a user, that straddles the set point.
- the electronic controller device 18 does not need direct inputs from a dedicated temperature sensor to operate and function as designed.
- the temperature sensing capability of the existing thermostat or thermostats in the system, or systems that include a remote sensor(s) that is capable of transmitting such information to the thermostat(s) for processing by that unit(s), can be relied on for the systems of the present invention.
- a temperature signal can be estimated from OEM control signal timing and existing ASHRAE or similar data for setpoint and hysteresis temperature values.
- FIG. 1 shows a single control line 15 cut and connected from a single thermostat 14 and connected to the electronic controller device 18 for simplification, it will be appreciated that in single or dual thermostat configurations, multiple control lines from a single thermostat, or a single control line from each of multiple thermostats each can be cut and separately connected to the electronic controller device 18, such as different respective input pins of the electronic controller.
- an output signal control line can be connected at one end to electronic controller device 18 and at the other end to the load control switches of each load device. For example, although only one load unit 20 under the load control and management of electronic controller device 18 in a single control signal line is shown in the HVAC&R system 11 of FIGS.
- the HVAC&R system 11 can include multiple individual loads under thermostat control, such as, for example, multiple compressors, or a compressor unit and a blower, and other similar or diverse loads, depending on the configuration.
- the electronic controller of this invention can be wholly connected in the control lines of individual subloads of the equipment.
- an air conditioner may have a separate control line for the subloads of the compressor unit and the blower unit.
- the electronic controller can be used to control either one or both of these subloads.
- the overall power line to all the subloads of the air conditioning unit is generally not in any way altered by the electronic controller of this invention.
- the usual conventional electrical grounding means is not shown in the schematic diagram of FIG. 1 as it is not a matter of particular concern in this invention.
- a stand-alone configuration can be used, for example, in a single load unit residential application (e.g., ⁇ about 5 ton HVAC& load unit).
- a networked configuration can be used, for example, as part of a building management system (BMS) for providing HVAC&R in a larger scale applications, such as higher energy use/demand residential, commercial or industrial buildings or equipment, and the like, or, as a network of electronic controllers, each attached to a dedicated load unit.
- BMS building management system
- the electronic controller device 18 in FIG. 1 includes at least one microprocessor operable to receive thermostat input signals, apply the indicated programs to thermostat signals received, and transmit an output signal under the command of the microcontroller to the HVAC&R load unit to be controlled.
- the microcontroller 183 which is included in controller device 18 in FIG. 1 , can include, for example, a microprocessor for storing and executing the indicated the indicated demand regulator controller program, as well as performing data collection function, controlling signal generation to the load device(s), and calculating the demand savings.
- microcontroller 183 can include a microprocessor 1832, a computer-readable storage medium 1833 shown as incorporating memory 1835, which all have been integrated in the same chip.
- Microprocessor 1832 also known as a central processing unit (CPU), contains the arithmetic, logic, and control circuitry needed to provide the computing capability to support the controller functions indicated herein.
- CPU central processing unit
- the memory 1835 of the computer-readable storage medium 1833 can include non-volatile memory, volatile memory, or both.
- Computer-readable storage medium 1833 can comprise at least one non-transitory computer usable storage medium.
- the non-volatile memory can include, for example, read-only memory (ROM), or other permanent storage.
- the volatile memory can include, for example, random access memory (RAM), buffers, cache memory, network circuits, or combinations thereof.
- the computer-readable storage medium 1833 of the microcontroller 183 can comprise embedded ROM and RAM. Programming and data can be stored in computer-readable storage medium 1833 including memory 1835.
- Program memory can be provided, for example, for the indicated demand regulator controller program 1837, and optionally other programs, such as a delayed start controller program 1836, excess time controller program 1831, and excess cycle controller program 1839, as well as store menus, operating instructions and other programming such as indicated herein, parameter values and the like, for controlling the controller device 18.
- Examples of the optional programs are shown, e.g., in WO 2014/152276 Al, which is incorporated herein in its entirety by reference. These programs can be stored in ROM or other memory.
- the indicated demand regulator controller program 1837, and other programs which can be optional, such as the indicated delayed start controller program 1836, excess time controller program 1831, and excess cycle controller program 1839, provide an integrated control program 1838 residing on controller device 18.
- Data memory such as FLASH memory
- Memory can be configured with data parameters. Memory can be used to store data acquired that is related to the operation of a load device to be controlled, such as thermostat command on times and calculated off times.
- the microprocessor 1832 and memory 1833 can be integrated and supported on a common mother board 1830, or the like, which can be housed in an enclosure (not shown) having input and output connection terminal pins, a communication link/interface connector port(s) (e.g., a mini-, or micro- or standard-size USB port for receiving a corresponding sized USB plug), and the like, which are discussed further with respect to FIG. 5.
- Microcontroller 183 can be, for example, an 8 bit or 16 bit or larger microchip microprocessor including the indicated microprocessor, and memory components, and is operable for input and execution of the indicated demand regulator controller program, and other included programs.
- Programmable microcontrollers can be commercially obtained to which the control program indicated herein can be inputted to provide the desired control. Suitable microcontrollers in this respect include those available from commercial vendors, such as Microchip Technology Inc., Chandler, AZ.
- microcontrollers examples include, for example, the PIC16F87X, PIC16F877, PIC16F877A, PIC16F887, dsPIC30F4012, and PIC32MX795F512L-801/PT, by Microchip Technology, Inc.; Analog Devices ADSP series; Jennie JN family; National Semiconductor COP8 family; Freescale 68000 family; Maxim MAXQ series; Texas Instruments MSP 430 series; and the 8051 family manufactured by Intel and others. Additional possible devices include FPGA/ARM and ASIC's.
- the demand regulator controller program indicated herein can be inputted to the respective microcontrollers using industry development tools, such as the MPLABX Integrated Development Environment from Microchip Technology Inc.
- controller device 18 is illustrated in FIG. 1 as a stand-alone unit tapped into the thermostat signal line 15 (24) to the load unit to be controlled, the indicated microelectronics of the controller optionally may be incorporated and integrated into the thermostat unit or a Building Management System (BMS).
- BMS Building Management System
- An algorithm incorporating the demand regulator controller program, and other indicated control programs and features of the electronic controller device can be added to native thermostat signal control software of the thermostat, or can be added to Building Management System (BMS) software where a BMS provides control to the load unit or units of the HVAC&R, eliminating a need for a physically separate electronic controller device.
- the interception of the OEM thermostat signal and processing thereof by the controller microelectronics can occur at the modified thermostat unit without the need for a physically separate microelectronic controller being tapped into the thermostat signal line 15 (24) between the thermostat and the load unit to be controlled.
- FIG. 3 An illustration of demand savings that can be obtained with an electronic controller device of the present invention is shown in FIG. 3. A cooling application is presented for this illustration.
- the compressor "off time should never become less than the compressor short cycle time, which is typically around 300 seconds.
- an "on-off" thermostat controlled cooling application where the thermostat controls the zone temperature between a high temperature value, "T-hi,” and a low temperature value, "T-lo,” is considered, such as indicated in FIG. 3.
- the thermostat forces the equipment “on” until the temperature reaches T-lo, then it forces the equipment “off until the zone temperature rises to T-hi, at which point the cycle repeats itself.
- the "on" time is measured to be 1200 seconds and the "off time 4800 seconds.
- the electrical current is directly proportional to the kW since voltage is ideally constant.
- the current is 0 amps when the equipment is "off or some constant value when the equipment is “on”.
- the Peak Demand is the Peak average kW measured over a 15 minute moving window on a monthly basis. Since kW is directly proportional to current and since current is controlled to either 0 (when the thermostat is "off) or a constant value (when the thermostat is "on"), a normalized Peak Demand value can be obtained using the thermostat control signal, designating 0 as "off and 1 as "on”. Using this normalization, if the thermostat commands the equipment to be "on” for greater than 900 seconds, then the Peak Demand becomes 100%. If the thermostat commands the equipment to be "on” for 450 seconds, then the Peak Demand becomes 50%.
- the electronic controller device of the present invention can interrupt and "chop up" the thermostat signal and pulse the equipment, such as by allowing it to run for 600 seconds “on”, and then turn “off for 300 seconds, then "on” for 600, “off for 300, and then "on” until T-lo is achieved. Assuming that the temperature varies linearly between T-hi and T-lo with respect to the "on” and "off times, the following behavior l)-3) occurs:
- an "on-off cycle requires 900 seconds and decreases the temperature from T-hi to (T-hi - T-lo) x 17/32.
- the temperature decrease is equal to (T-hi - T-lo) x 15/32.
- the demand regulator (DR) function of the controller device of the present invention uses pulsing to reduce the peak demand in a manner similar to that described above, except the pulse durations are computed by the algorithm to achieve a desired demand savings setpoint value.
- the demand regulator (DR) function is designed to limit the Peak Demand of the HVACR equipment at or below a configurable setpoint value. This is accomplished by "pulsing" the equipment command signal through a sequence of repeated “on” and “off cycles while the OEM command is calling for heating or cooling.
- FIG. 3 illustrates the behavior of the demand regulator (DR) function in this respect for a cooling application.
- the "pulsed" command signal, referred to as the "Pace” control signal in FIG. 3, which is sent to the load unit equipment is created by the demand regulator (DR) function of the electronic controller device of the present invention.
- T* is the zone temperature setpoint
- T-hi T* + 1 degF (°F)
- T-lo T* - 1 degF
- Pulsing is the savings mechanism that results in the ability to control (or regulate) the Peak Demand and save on the cost of electricity.
- HVACR HVACR
- pulsing the fuel flow will reduce stack temperature overshoot by reducing the overall fuel flow rate to the equipment which, in turn, reduces the rate of change of the stack temperature and the waste heat passing through the stack. Temperatures moving towards a setpoint at a reduced rate will exhibit less overshoot and undershoot. The net result is a reduction in fuel usage.
- HVAC equipment compressors, blowers, igniters, and so forth
- nkMax is a parameter used in the algorithm that defines the maximum equipment starts per hour. Typically this value is between 4 and 8, however, it is adjustable.
- Short cycling means the equipment is cycled ON and OFF rapidly.
- Short cycle control is enforced by placing a lower limit on the tOff value. This prevents the equipment from being turned ON in any less than tOff time units since the last time it was turned OFF.
- Typical values for the short cycle time, tShortCycle are 2 to 3 minutes depending on the type of equipment.
- a demand control problem which is addressed by the present invention, can be stated as follows: Adjust tOn and tOff to meet the setpoint demand while limiting nk (the number of equipment starts per hour) to be less than or equal to nkMax.
- the demand control algorithm of the demand regulator controller of the present invention can solve this problem in an example which has steps l)-4) as follows:
- Step 1) nkMax and tShortCycle are defined as constant parameters. tOff is initialized to tShortCycle.
- Step 2) Calculate tOn needed to meet the demand setpoint D* and tOff:
- Step 3 Calculate nk (the number of equipment starts per hour),
- Step 4) Calculate the excess starts per hour as: nk - nkMax, and if the excess starts per hour is > 0, then increase tOff.
- the value of tOff can be increased an amount of from about 180 seconds to about 600 seconds, or from about 200 seconds to about 500 seconds, or from about 250 seconds to about 400 seconds, or other amounts, from a value thereof used in the previous iteration through steps 2)-4).
- the upper limit value of the increased pulse off-time, tOff is limited to a time required for the number of equipment starts per hour to equal the maximum equipment starts per hour.
- the increased value of tOff is then used in Steps 2) and 3) to recalculate the tOn value, then nk, then excess starts per hour, and these series of calculations are repeated iteratively, until the indicated nkMax constraint is satisfied.
- FIG. 4A A block flow diagram is shown in FIG. 4A of process control logic for the operation of the demand regulator controller of the electronic controller device according to an example of the present invention.
- a glossary of block elements in FIG. 4A is provided in the table in FIG. 4B.
- This process control logic implements the indicated steps 1) - 4).
- the demand setpoint (“D*) and maximum number of equipment starts per hour (“nkMax”) are used as input in the process flow logic 100 with tOff initialized to tShortCycle.
- electrical demand typically is calculated as the total "on" time during a 15 minute interval or other time interval window used for demand measurement.
- the demand regulator controller can estimate the "worst case” demand which is the condition where the controller is continuously cycling during the entire 15 minute interval.
- the short cycling condition time (tShortCycle) typically can be set as a value in the range of from 3 - 4 minutes, or other time.
- the short cycling time can correlate to a time period that allows a load unit to sufficiently rest between duty "on" times. This time may correspond to a time period for oil to circulate through a refrigeration system or other device recovery period.
- the worst case demand becomes more accurate as the load increases and less accurate at lower loads, however, it always estimates the worst case demand which is greater than the actual demand.
- the tOn value needed to meet the demand setpoint D* is calculated (see, e.g., above- indicated step 2)).
- nk (the number of equipment starts per hour) is calculated using the calculated tOn value (see, e.g., above-indicated step 3)).
- D* demand setpoint
- tOn time also will be reduced and nk increases.
- the excess starts per hour are calculated as nk - nkMax and the result is checked to see if it exceeds zero (see, e.g., above-indicated step 4)). If the excess starts per hour is greater than 0, then tOff is increased, and the increased tOff value is used another iteration of the indicated successive calculations for tOn and nk.
- tOff reduces the nk value obtained in the next iteration of calculations. Accordingly, the increased value of tOff is used to recalculate the tOn value, then nk, then compared to the maximum excess starts per hour (nkMax) to see if the number of starts nk is more than nkMax, and these series of calculations are repeated iteratively until an nk value is obtained that satisfies the indicated nkMax constraint (i.e., nk ⁇ nkmax), at which point the tOn and tOff time values of that iteration are used for control signals sent to the load unit.
- the indicated nkMax constraint i.e., nk ⁇ nkmax
- the demand regulator (DR) controller of the present invention can adjust the controller-output "on” (tOn) and “off' (tOff) times that are sent to the load unit such that a desired preselected electrical demand can be achieved.
- the algorithm of the demand controller of the present invention can constrain the "on" (tOn) and “off' (tOff) times that the controller device sends to the load unit to determine an excess number of starts nk that can reduce load unit demand while avoiding short cycling the load unit.
- An adjusted control signal generated in this respect by the electronic controller can be outputted to a controller switch of at least one load unit to control operation of the load unit.
- FIG. 5 shows an electrical connection diagram 1000 for a single stage cooling application using an electronic controller device according to an example of the present invention.
- This configuration can be used when a single air conditioner thermostat is used to control one HVAC cooling device (a compressor).
- HVAC cooling device a compressor
- This configuration also supports thermostats that provide a manual switch to select either heating or cooling operation.
- the compressor can be a compressor suitable for use in vapor- compression cooling/refrigeration systems.
- the compressor can include an electric motor (not shown), used to drive the compressor.
- the electric motor itself can be a conventional electric motor or other suitable electric motor used or useful for driving such load units.
- the electronic controller device 1018 provides two independent control channels that may be wired to support different equipment configurations.
- the first channel 1001 A comprises one of pins 1-3
- the second channel 100 IB comprises one of pins 4-6 thereof.
- Output lines to the load unit(s), e.g., a cooling unit compressor, are shown as extending from one of pins 4-6.
- the controller provides a separate "dry contact" input channel that may be used for remote control of the controller, such as by an existing BMS system.
- pins 1-2 thereof can be used for this dry contact input module.
- a communication port 1020 is shown in these figures as a mini-USB port (e.g., a camera size USB port) but is not limited thereto.
- a service tool (not shown) can be used to import/input parameters, and the like into the electronic controller device 1018 by making a communication link with the controller via port 1020.
- the electronic controller device 1018 can have the indicated demand regulator controller program preloaded into the controller on-board memory during its assembly and before installation in the field.
- the thermostat e.g., an OEM thermostat
- the thermostat which can be used with the electronic controller device of the present invention, such one having the wiring configuration shown in FIG. 5 or another configuration, can deployed at some point in a building and senses the temperature of the ambient air and if it is higher than the comfort setting which has been selected, sends a signal to activate the air conditioning unit.
- the electronic controller device intercepts the thermostat signal, which powers up the electronic controller device to process the signal according to the programmed algorithm of the demand regulator controller before sending a controller-processed output signal to the load unit.
- the air conditioning unit typically comprises the compressor, and a condenser and evaporator connecting with each other in a closed refrigerant system (not shown).
- the refrigeration cycle itself is well known (e.g., see, U.S. Patent No. 4,094,166, which is incorporated herein by reference in its entirety).
- gaseous refrigerant is delivered from the compressor to the condenser coil where it gives up heat and then is passed through an expansion valve to the evaporator coil where it absorbs heat from the circulating air which is passed thereover by the evaporator fan.
- the thermostat senses that the ambient air has been cooled to the selected level, the thermostat goes to an off state to turn off the compressor, evaporator fan and condenser fan until the ambient temperature has again reached the level where further cooling is necessary.
- the electronic controller device of the present invention goes to sleep when the thermostat stops signaling the load unit, until the next power on signal is sent by the thermostat to the same load unit which, as indicated, will be intercepted by the electronic controller device which powers up the electronic controller device to process the signal according to its programmed algorithm before sending a controller-processed output signal to the load unit.
- a deadband typically is applied to the control temperature setting at the thermostat, which deadband effectively can be modified by the electronic controller device to improve demand savings in a controlled manner.
- the indicated pin assignments for the first channel 1001 A and second channel 100 IB that are identified in FIG. 5 can apply in similar pin module for other types of load units of an HVACR system, such as a dual stage cooling unit, a heating unit (e.g., gas, electric, heat pump), a boiler, and so forth.
- Other aspects of an electrical connection configuration that can be used in these other types of load units can be readily adapted and implemented as applicable.
- an electronic controller device having the indicated demand regulator controller is operable to intercept and process a thermostat's control signal with an algorithm that can automatically generate enhanced control signals to provide demand control.
- existing HVAC&R systems for example, can embody the present controller such as illustrated herein to improve energy consumption and reduce energy costs of heating, cooling, and refrigeration equipment.
- the present invention includes the following aspects/embodiments/features in any order and/or in any combination:
- the present invention relates to a method for demand control of at least one duty cycled HVAC/R equipment powered by electricity with limiting of equipment unit starts per time interval, comprising:
- step iv) when the calculated value of excess starts per hour is greater than zero, then pulse off-time is increased an amount of from about 180 seconds to about 600 seconds from a value used in the previous iteration through steps ii)-iv), wherein an upper limit value of the increased pulse off-time is limited to a time required for the number of equipment starts per hour to equal the maximum equipment starts per hour.
- peak demand for the load unit can be reduced at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 35%, or at least 40%, or at least 50%, or from 10% to 50%, or from 10% to 40%), or from 15% to 35%, as compared to operation of the load unit with the thermostat command signals over the same time period, wherein peak demand is computed as the peak average kW measured over a 15 minute moving window on a 30 day monthly basis.
- the load unit comprises a compressor, a blower, or igniter.
- the present invention further relates to a method for demand control of at least one duty cycled HVAC/R equipment powered by electricity with limiting of equipment unit starts per time interval, comprising:
- step l)-4 determining a pulsed command signal that is transmitted to the load unit for automatically controlling the load unit while the thermostat command signal is calling for heating, cooling or refrigeration duty by the load unit, wherein the pulsed command signal comprises alternating pulse on and pulse off cycles which have respective durations that are determined according to demand regulator computations comprising steps l)-4), which comprise:
- pulse off-time is the short cycle time in a first iteration through step 2) or an increased value for the pulse off-time from step 4) from an immediate previous iteration of steps 2)-4),
- the pulse off-time is the short cycle time in a first iteration through step 2) or an increased value for the pulse off-time from step 4) from an immediate previous iteration of steps 2)-4),
- nk - nkMax if the calculated value of excess starts per hour is > 0, then the difference (nk - nkMax) is integrated, scaled, and added to the short cycle time to create a new increased off-time value and the new increased pulse off-time is then used as the pulse off-time in steps 2) and 3) iteratively to recalculate the pulse on-time value and number of starts per hour until the maximum equipment starts per hour is satisfied wherein nk— nkMax ⁇ 0, wherein the durations of the pulse on cycle and pulse off cycle of the pulse command signal are established as corresponding to the on-time and off-time, respectively, in the computations when the maximum equipment starts per hour is satisfied; and c) replacing the thermostat command signal with the pulsed command signal determined in step 4).
- step 4 when the calculated value of excess starts per hour is > 0, then pulse off-time is increased an amount of from about 180 seconds to about 600 seconds from a value thereof used in the previous iteration through steps 2)-4), wherein an upper limit value of the increased pulse off-time is limited to a time required for the number of equipment starts per hour to equal the maximum equipment starts per hour.
- peak demand for the load unit can be reduced at least 10%, or at least 15%», or at least 20%, or at least 25%, or at least 35%, or at least 40%, or at least 50%, or from 10% to 50%, or from 10% to 40%, or from 15% to 35%, as compared to operation of the load unit with the thermostat command signals over the same time period, wherein peak demand is computed as the peak average kW measured over a 15 minute moving window on a 30 day monthly basis. 14.
- peak demand for the load unit can be reduced at least 25% as compared to operation of the load unit with the thermostat command signals over the same time period, wherein peak demand is computed as the peak average kW measured over a 15 minute moving window on a 30 day monthly basis.
- the load unit comprises a compressor, a blower, or igniter.
- the electronic controller device has at least one input connector for attaching at least one thermostat signal line and at least one output connector for attaching at least one signal line for outputting the pulse command signal to the load unit.
- the present invention relates to an electronic controller device for demand control of a duty cycled HVAC/R equipment with limiting of equipment starts per time interval, comprising:
- the controller device intercepts a thermostat command signal in-route to the load unit and replaces the thermostat command signal with a pulsed command signal that is transmitted to the load unit for automatically controlling the load unit while the thermostat command signal is calling for heating, cooling or refrigeration duty by the load unit, wherein the pulsed command signal comprises alternating pulse on and pulse off cycles which have respective durations that are determined according to demand regulator computations that are performed with at least one processor and at least one memory storing instructions, the instructions comprising one or more instructions which, when executed by the at least one processor, cause the at least one processor to execute steps comprising steps i)-iv), which comprise i) inputting maximum equipment starts per hour, short cycle time, and demand setpoint, and initializing pulse off-time to the short cycle time, ii) calculating pulse on-time needed to meet the demand setpoint and the pulse off-time,
- the present invention relates to an electronic controller device for demand control of a duty cycled HVAC/R equipment with limiting of equipment starts per time interval, comprising:
- the controller device intercepts a thermostat command signal in-route to the load unit and replaces the thermostat command signal with a pulsed command signal that is transmitted to the load unit for automatically controlling the load unit while the thermostat command signal is calling for heating, cooling or refrigeration duty by the load unit, wherein the pulsed command signal comprises alternating pulse on and pulse off cycles which have respective durations that are determined according to demand regulator computations that are performed with at least one processor and at least one memory storing instructions, the instructions comprising one or more instructions which, when executed by the at least one processor, cause the at least one processor to execute steps comprising steps l)-4), which comprise: 1) inputting maximum equipment starts per hour (nkMax), short cycle time and demand setpoint (D*), and initializing pulse off-time (tOff) to the short cycle time, 2) calculating pulse on-time itOri) needed to meet the demand setpoint
- controller device capable of intercepting a thermostat command signal in-route for at least one of a compressor, blower, or igniter, and replacing the thermostat command signal with the pulse command signal.
- the present invention relates to a heating, ventilating, air conditioning or refrigeration (HVAC&R) system comprising a heating, ventilating, air conditioning or refrigeration unit and the electronic controller device that intercepts a thermostat control signal of the HVAC&R system and applies a demand regulator function that is capable of setting pulse off-time and on-time values to satisfy a selected electrical demand set point.
- HVAC&R heating, ventilating, air conditioning or refrigeration
- peak demand for the load unit can be reduced at least 10% as compared to operation of the load unit with the thermostat command signals over the same time period, wherein peak demand is computed as the peak average kW measured over a 15 minute moving window on a 30 day monthly basis.
- the present invention can include any combination of these various features or embodiments above and/or below as set forth in sentences and/or paragraphs. Any combination of disclosed features herein is considered part of the present invention and no limitation is intended with respect to combinable features. [0069] The present invention will be further clarified by the following examples, which are intended to be exemplary of the present invention.
- Performance was evaluated as follows. A simulation of an operation of a single stage cooling system, wherein a single thermostat is used to control one compressor, such as shown in FIG. 5, was performed with an electronic controller device having a demand regulator controller of the present invention. The simulation was performed on a computer model that was developed using VisSim software, obtained from Visual Solutions of Westford, MA, USA. The developed program was adapted to simulate operation of the electronic controller that applies the process control logic shown in FIG. 4A herein. The developed model was based in part on actual data obtained from operation of the same equipment in the indicated single stage cooling configuration and with the OEM thermostat alone in the field. The simulation model is calibrated to agree with field data.
- the plot in FIG. 6 A shows the demand with respect to demand set point (D*) ("o" trace lines) and actual demand (Demand Response, fraction)("x" trace lines) over a period time for the simulated control.
- the plot in FIG. 6B shows an enlarged portion of a portion of the plot of FIG.
- the plot in FIG. 7 shows the on time (tOn) ("o" trace lines) and off time (tOff) ("x" trace lines) behavior over a period time for the simulated control shown in FIG 6A.
- the plot of FIG. 8 shows the equipment starts per hour (nk) performance over a period of time for the simulated control shown in FIG. 6 A.
- the Demand setpoint, D* was modified in step increments beginning at 100%, dropping to 20%, and then increasing back to 90%.
- FIG. 9 shows the demand with respect to demand set point (Demand Command, fraction), D*, ("o" trace lines) and actual demand (Demand Response, fraction) ("x" trace lines) over a period time for the simulated control, with a maximum equipment starts per hour (nkMax) of 4 at time 0 to 40,000 seconds, a maximum equipment starts per hour (nkMax) of 8 for the time period 40,000 to 60,000 seconds, and a maximum equipment starts per hour (nkMax) of 4 at time 60,000 seconds onward.
- the plot of FIG. 10 shows the on time (tOn) ("o" trace lines) and off time (tOff) ("x" trace lines) behavior over a period time for the simulated control.
- the plot of FIG. 11 shows the equipment starts per hour (nk) performance over a period of time for the simulated control.
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Abstract
L'invention concerne un procédé pour gérer automatiquement et pour fournir une régulation de la demande d'équipement CVC et R à cycle de service d'une manière améliorée par rapport à un fonctionnement ayant une régulation thermostatique propre, la consommation de la demande électrique pouvant être commandée par l'exercice de la commande de cycle de service d'un système de marche/arrêt. Un dispositif de commande électronique peut être utilisé en tant que dispositif supplémentaire dans des systèmes CVC et R à régulation thermostatique qui gère automatiquement et fournit la régulation de demande d'équipement CVC et R à cycle de service.
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US4934196A (en) * | 1989-06-02 | 1990-06-19 | Micro Motion, Inc. | Coriolis mass flow rate meter having a substantially increased noise immunity |
WO1997037246A1 (fr) * | 1996-03-29 | 1997-10-09 | Schlumberger Technology Corporation | Flute sismique a reference de fond, equipee de lignes verticales d'hydrohones |
US20110321175A1 (en) * | 2010-06-23 | 2011-12-29 | Salesforce.Com, Inc. | Monitoring and reporting of data access behavior of authorized database users |
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WO2014152276A1 (fr) * | 2013-03-15 | 2014-09-25 | Pacecontrols Llc | Organe de commande pour la commande automatique d'un équipement de cvca et r à cycle de service, et systèmes et procédés utilisant celui-ci |
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US4934196A (en) * | 1989-06-02 | 1990-06-19 | Micro Motion, Inc. | Coriolis mass flow rate meter having a substantially increased noise immunity |
WO1997037246A1 (fr) * | 1996-03-29 | 1997-10-09 | Schlumberger Technology Corporation | Flute sismique a reference de fond, equipee de lignes verticales d'hydrohones |
US20110321175A1 (en) * | 2010-06-23 | 2011-12-29 | Salesforce.Com, Inc. | Monitoring and reporting of data access behavior of authorized database users |
US20130271289A1 (en) * | 2012-04-13 | 2013-10-17 | International Business Machines Corporation | Anomaly detection using usage data for metering system |
WO2014152276A1 (fr) * | 2013-03-15 | 2014-09-25 | Pacecontrols Llc | Organe de commande pour la commande automatique d'un équipement de cvca et r à cycle de service, et systèmes et procédés utilisant celui-ci |
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