WO2022204262A1 - Système et procédé de diagnostic et de surveillance de réseaux de ventilateurs - Google Patents

Système et procédé de diagnostic et de surveillance de réseaux de ventilateurs Download PDF

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Publication number
WO2022204262A1
WO2022204262A1 PCT/US2022/021516 US2022021516W WO2022204262A1 WO 2022204262 A1 WO2022204262 A1 WO 2022204262A1 US 2022021516 W US2022021516 W US 2022021516W WO 2022204262 A1 WO2022204262 A1 WO 2022204262A1
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WO
WIPO (PCT)
Prior art keywords
control module
parameter value
parameter
motor controller
motor
Prior art date
Application number
PCT/US2022/021516
Other languages
English (en)
Inventor
Timothy NYGAARD
Original Assignee
Coil Master Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US17/685,976 external-priority patent/US20220307712A1/en
Application filed by Coil Master Corporation filed Critical Coil Master Corporation
Priority to CA3232443A priority Critical patent/CA3232443A1/fr
Publication of WO2022204262A1 publication Critical patent/WO2022204262A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D25/00—Pumping installations or systems
    • F04D25/16—Combinations of two or more pumps ; Producing two or more separate gas flows
    • F04D25/166—Combinations of two or more pumps ; Producing two or more separate gas flows using fans
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
    • F04D27/001—Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring

Definitions

  • This disclosure relates generally to air-handling systems. More specifically, this disclosure relates to diagnostic and monitoring systems for fan arrays.
  • Air-handling systems are utilized to move air according to desired ventilation parameters for the environment of the system.
  • the air-handling systems can be controlled to provide desired volumetric flow rate and desired pressure for the environment.
  • One example of an air handling system is a unit including components configured to work together to condition air as part of a primary ventilation system for structures, such as a rooftop unitary system. Some examples include stand-alone fan assemblies for moving air.
  • Air-handling systems can utilize one or more fan arrays formed from multiple individual fans to move the air instead of a single fan structure. The individual fans form a fan array and work in parallel to generate the required output from that fan array.
  • the individual fans forming a fan array can be electronically operated.
  • a variable frequency drive can be used to vary the speeds of the fans in the fan array.
  • Some examples can include fans powered by electronically commutated (EC) motors. Powering the individual fans with EC motors provides direct control over the individual fans.
  • the parallel operation of the fans forming a fan array means that the operating parameters of each of the individual fans need to be accurate for the fan array and air-handling system including that fan.
  • the operating parameters of each EC motor can be set according to the particular fan array and system that the fan is within.
  • the operating parameters can be field-programmable to be changed in case a fan requires replacement, repair, or redeployment.
  • a method of fan array control includes generating, by a control module, a first parameter status inquiry and sending the first parameter status inquiry to a first motor controller of a first fan assembly of a first fan array; receiving, at the control module, a first actual parameter value of a first operating parameter from the first motor controller; comparing, by the control module, the first actual parameter value and a first expected parameter value of the first operating parameter; determining, by the control module, a parameter status of the first motor controller based on the comparison of the first actual parameter value and the first expected parameter value; and writing, by the control module, the first expected parameter value to the first motor controller as the first actual parameter value of the first operating parameter based on the parameter status being an invalid parameter status.
  • an air handling system includes a first fan array and a control module including control circuitry and memory.
  • the first fan array includes a first fan assembly having a first motor operatively connected to a first impeller, the first motor including a first motor controller; and a second fan assembly having a second motor operatively connected to a second impeller, the second motor including a second motor controller.
  • the control module is operatively connected to the first fan assembly and the second fan assembly.
  • the control module is configured to generate a first parameter status inquiry; send the first parameter status inquiry to the first motor controller; receive a first actual parameter value from the first motor controller in response to the first parameter status inquiry; compare the first actual parameter value and a first expected parameter value; determine a parameter status of the first motor controller based on the comparison of the first actual parameter value and the first expected parameter value; and write the first expected parameter value to the first motor controller as the first actual parameter value based on the parameter status of the first actual parameter value being an invalid parameter status.
  • a diagnostic and monitoring method for an air-handling system includes determining, by a control module and for a first fan array including a plurality of first fan assemblies, a plurality of parameter statuses of a plurality of first motor controllers of each first fan assembly of the plurality of first fan assemblies based on a comparison of a first actual parameter value received from the first motor controller and a first expected parameter value recalled from a memory of the control module; wherein the control module is configured to determine a parameter status of a target first motor controller prior to determining a parameter status of a next first motor controller.
  • FIG. 1 A is a schematic block diagram of an air-handling system, according to an example of the present disclosure.
  • FIG. IB is a schematic block diagram of a fan array and controller, according to an example of the present disclosure.
  • FIG. 2 is a method of diagnosing and monitoring fan assemblies, according to an example of the present disclosure.
  • FIG. 3 is a method of initiating a parameter correction, according to an example of the present disclosure.
  • FIG. 4 is a method of autonomously initiating a parameter correction, according to an example of the present disclosure.
  • Air-handling systems include one or more fan arrays to generate the required airflow for the environment of the air-handling system.
  • Fan arrays are formed by multiple individual fan assemblies that are each powered by an electronically commutated (EC) electric motor.
  • the EC motor is connected to an impeller to power the rotation of the impeller.
  • Each impeller can be in a direct drive arrangement with its motor.
  • the multiple fan assemblies of a fan array operate in parallel to provide the desired airflow output for the portion of the air-handling system formed by the fan array.
  • Each EC motor includes a dedicated motor controller to control the output of the fan assembly of that EC motor.
  • a system controller controls operation of each fan assembly by way of the motor controller of that fan assembly.
  • FIG. 1A is a schematic block diagram of air-handling system 10.
  • FIG. IB is a schematic block diagram of fan array 12.
  • FIGS. 1 A and IB will be discussed together.
  • Air handling system 10 includes fan arrays 12, control module 14, and user interface 16.
  • Each fan array 12 includes a plurality of fan assemblies 18.
  • Each fan assembly 18 includes motor 20 (FIG. IB), motor controller 22 (FIG. IB), and impeller 24 (FIG. IB).
  • the example fan array 12a is shown in FIG.
  • Fan assembly 18 includes fan assemblies 18a-18n (collectively herein “fan assembly 18” or “fan assemblies 18”).
  • Fan assembly 18a includes motor 20a, motor controller 22a, and impeller 24a.
  • Fan assembly 18b includes motor 20b, motor controller 22b, and impeller 24b.
  • Fan assembly 18n includes motor 20n, motor controller 22n, and impeller 24n.
  • Air-handling system 10 is configured to move air in an environment according to desired ventilation parameters.
  • air-handling system 10 can be utilized in locations such as higher education facilities, data centers, healthcare facilities, pharmaceutical facilities, hospitals, manufacturing facilities, among other applications.
  • Air-handling system 10 can be configured to provide desired volumetric flow rate and/or desired static pressure for the environment.
  • Air-handling system 10 includes fan arrays 12.
  • Fan arrays 12 are configured to move the air based on the desired ventilation parameters.
  • a fan array 12 can be used to move air for intake, exhaust, exchange, pressurization, etc.
  • the example shown includes fan array 12a, fan array 12b, and fan array 12n.
  • the letter “n” with respect to fan arrays 12a-12n represents an arbitrary number, such that air-handling system 10 can include any number of fan arrays 12, including a single fan array 12. As such, air-handling system 10 can include one fan array 12 or multiple fan arrays 12.
  • a ventilation unit for a building can include a stand-alone fan array 12 disposed in a wall and configured to draw air into and/or exhaust air from an interior of the building.
  • air-handling system 10 can include and/or be formed as rooftop unitary equipment configured to condition air.
  • One or more of the fan arrays 12 can be integrated into air-handling units, such as a first fan array 12 forming an intake array and a second fan array 12 forming an exhaust array.
  • Each fan array 12 includes multiple fan assemblies 18.
  • fan array 12a includes fan assemblies 18a-18n.
  • the letter “n” with respect to fan assemblies 18a-18n represents an arbitrary number, such that each fan array 12 can include two or more fan assemblies 18.
  • Fan assemblies 18 are individual units that are arranged in parallel to generate the airflow for the fan array 12 formed by the multiple fan assemblies 18.
  • Each fan array 12 forming air-handling system 10 can include the same number of fan assemblies 18 or different numbers of fan assemblies 18.
  • Each fan assembly 18 includes motor 20 and impeller 24.
  • Impeller 24 is operably connected to motor 20 to be driven by motor 20.
  • Fan assembly 18 can be of any desired configuration for generating pressurized airflow.
  • impeller 24 can be configured as an axial flow or centrifugal flow impeller.
  • Motor 20 generates a rotational output to drive rotation of the impeller 24, which generates the airflow.
  • Motor 20 is an electronically commutated (EC) motor that includes a rectifier to convert an AC power supply to DC power and a motor controller 22.
  • the motor controller 22 directs the current to the windings of a stator of the motor 20 to drive the rotation of the rotor.
  • Motor controller 22 regulates the current to the windings to control the torque generated and the rotational speed of motor 20.
  • the rotor is connected to the impeller 24 to drive rotation of the impeller 24, such as by a direct drive arrangement.
  • Each motor controller 22 is a control device configured to monitor and control the operation of its associated motor 20 to cause fan assembly 18 to generate an airflow having desired flow characteristics.
  • Motor controller 22 controls the speed of impeller 24, thereby controlling the volumetric air flow and pressure generated by fan assembly 18.
  • Motor controller 22 can also be referred to as a speed controller of the EC motor 20.
  • Control module 14 is a control device operably connected to other components of air-handling system 10, such as motor controllers 22. Control module 14 can be electrically and/or communicatively connected to the components of air-handling system 10 for monitoring and control of the components during operation of air-handling system 10. Control module 14 is configured to control the operation of the fan arrays 12 to generate the airflow required by air-handling system 10.
  • a master control module 14 can be operably connected to dedicated fan array control modules 14, and each of the fan array control modules 14 can be associated with one or more fan arrays 12. In some examples, control module 14 can be configured to also control the operation of air-handling components of air-handling system other than fan arrays 12.
  • Control module 14 can be of any desired configuration for controlling the operation of one or more fan arrays 12 and can include control circuitry and memory. Control module 14 is configured to store executable code, implement functionality, and/or process instructions. Control module 14 is configured to perform any of the functions discussed herein, including controlling operation of any components referenced herein. Control module 14 can be of any suitable configuration for controlling the operation of fan arrays 12, gathering data, processing data, etc. Control module 14 can include hardware, firmware, and/or stored software. Control module 14 can be of any type suitable for operating in accordance with the techniques described herein. While control module 14 is illustrated as a single unit, it is understood that control module 14 can be entirely or partially mounted on one or more boards. In some examples, control module 14 can be implemented as a plurality of discrete circuitry subassemblies.
  • each of control module 14 and motor controllers 22 includes one or more processors and computer- readable memory.
  • the one or more processors can include any one or more of a microprocessor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry.
  • DSP digital signal processor
  • ASIC application specific integrated circuit
  • FPGA field-programmable gate array
  • Computer-readable memory can be configured to store information during operation.
  • the computer-readable memory can be described, in some examples, as computer- readable storage media.
  • a computer-readable storage medium can include a non-transitory medium.
  • the term “non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal.
  • a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache).
  • Computer-readable memory of control module 14 and/or motor controller 22 can include volatile and non-volatile memories. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories.
  • RAM random access memories
  • DRAM dynamic random access memories
  • SRAM static random access memories
  • non-volatile memories can include magnetic hard discs, optical discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.
  • EPROM electrically programmable memories
  • EEPROM electrically erasable and programmable memories
  • the memory is used to store program instructions for execution by the control circuitry.
  • the memory in one example, is used by software or applications running on the control module 14 or motor controller 22 to temporarily store information during program execution.
  • Control module 14 is communicatively connected to motor controllers 22, such as by one or both of wired and wireless communications networks.
  • control module 14 and motor controllers 22 can be configured to communicate utilizing radiofrequency (RF) communications.
  • the communications circuitry can be configured for communications utilizing short- wavelength ultra high frequency (UHF) radio waves in the 2.4 GHz band (2.400-2.525 GHz) (e.g., Bluetooth® communications).
  • the communications circuitry can be configured for communications utilizing super high frequency (SHF) radio waves in the 5GHz band. It is understood, however, that control module 14 and motor controllers 22 can be configured to communicate in any desired manner utilizing any suitable frequency.
  • Control module 14 can be configured as an input and/or output device.
  • user interface 16 can be configured to receive inputs from a user and/or provide outputs including information generated and/or provided by control module 14.
  • Examples of user interface 16 can include one or more of a sound card, a video graphics card, a speaker, a display device (such as a liquid crystal display (LCD), a light emitting diode (LED) display, an organic light emitting diode (OLED) display, etc.), a touchscreen, a keyboard, a mouse, a joystick, buttons, dials, or other type of user interface device for facilitating input and/or output of information in a form understandable to users or machines.
  • User interface 16 can be integrated with control module 14 or formed as a separate device.
  • user interface 16 can be a smartphone, tablet, or other such device.
  • User interface 16 can be connected to control module 14 by wired and/or wireless communications networks.
  • Air-handling system 10 is operated to provide desired airflow for the environment associated with air-handling system 10.
  • Fan arrays 12 are controlled based on desired volumetric flow and/or static pressure, among other ventilation parameter options.
  • Control module 14 is configured to generate and/or provide control signals to the motor controllers 22 to control operation of the various fan assemblies 18.
  • Control signals are provided to the motor controllers 22 to individually control operation of each fan assembly 18.
  • the control signals provide various commands to the motor controllers 22 to control operation of the motor 20 to alter the flow and pressure from that fan assembly 18.
  • the motor controllers 22 operate the associated motors 20 based on the commands provided by the control signals.
  • the control signals from control module 14 provide instructions to motor controllers 22 to cause motor controllers 22 to operate motors 20.
  • control signals can provide speed commands to the motor controllers 22 to cause the motor controllers 22 to adjust a speed of an associated motor 20.
  • Each motor controller 22 has one or more associated motor operating parameters that are stored in the memory of that motor controller 22.
  • the motor operating parameters can provide instructions to the motor controller 22 for interpreting and implementing commands received from control module 14.
  • Each motor controller 22 controls operation of its associated motor 20 based on the one or more motor operating parameters.
  • the motor operating parameters are stored in non-volatile memory of the motor controller 22.
  • the motor operating parameters of each motor 20 can be stored in the memory of the motor controller 22 of that motor 20 in a read-write format.
  • the motor operating parameters can define operational limits (e.g., speed, acceleration, etc.) regarding motor 20.
  • the motor operating parameters can include, among other options, demand source selection (e.g., analog control signal, digitally communicated control signal, which input, etc.); fan enable selection (e.g., whether an external contact is required to run the fan, and if so, which one, whether close or open contact enables operation, etc.); operating mode (e.g., open loop modulation, closed loop speed control, based on an internal or external sensor, etc.); ramp-up time (e.g., maximum allowable acceleration rate); ramp-down time (e.g., maximum allowable deceleration rate); demand signal curve (e.g., minimum desired speed, maximum desired speed, which analog signals correspond to minimum/maximum/other speed, etc.); signal break voltage (e.g., minimum voltage for a valid demand signal); fail-safe control mode (operating state when demand signal lost/invalid); fail-safe speed (desired speed if operating in fail-
  • the motor operating parameters for each motor controller 22 are set to desired values such that the command signals from control module 14 produce the desired response and output from the motor controller 22 receiving the command.
  • the motor controllers 22 are intended to have expected operating parameters and expected operating parameter values.
  • the expected operating parameters are the motor operating parameters that motor controller 22 is intended to have stored in its memory.
  • the expected operating parameter values are the values for each motor operating parameter that the motor controller 22 should have stored in memory to properly interpret command signals.
  • the control module 14 is configured to provide instructions to motor controllers 22 based on the expected parameter values.
  • the expected parameter values can vary from initial or manufacturer-set parameter values.
  • the expected parameter values for each fan array 12 and/or fan assembly 18 can be stored in the memory of control module 14 as the expected parameter configuration according to which the control module 14 provides instructions to the motor controllers 22.
  • the actual motor operating parameters are the motor operating parameters actually stored in the memory of a motor controller 22.
  • the actual operating parameter values are the motor operating parameter values that are actually stored in the memory of the motor controller 22.
  • the motor controller 22 interprets and reacts to instructions from the control module 14 based on the actual operating parameter values.
  • a first motor controller 22 can include stored motor operating parameters specifying that a 10V command signal is a maximum speed command and that the maximum speed is 2500RPM
  • a second motor controller 22 can include stored motor operating parameters specifying that an 8V command signal is a maximum speed command and that the maximum speed is 3000RPM.
  • the same 8V command signal provided to the first and second motor controllers 22 will cause different reactions and outputs from the fan assemblies 18 of those motor controllers 22.
  • each fan array 12 can be configured to have an array operating parameter configuration.
  • the array operating parameter configuration can provide the expected operating parameters and values for each motor controller 22 forming that fan array 12.
  • a fan array 12 can be configured such that each fan assembly 18 forming the fan array 12 is commonly configured.
  • each of motor controllers 22a-22n shown in FIG. IB can have the same expected parameter values.
  • each of motor controllers 22a- 22n can be configured to have the same demand signal curve such that the same command signal provides the same speed command to each fan assembly 18a-18n.
  • the expected parameter value stored in each motor controller 22 of fan assembly 18a can indicate that a 2V command signal is a minimum speed command and a 10V command signal is a maximum speed command.
  • Control module 14 is configured to generate and send instructions to motor controllers 22 based on the expected parameter values. Motor controllers 22 control the operation of the associated motors 20 based on the actual parameter values of that motor controller 22. The actual parameter values for each motor controller 22 should be the same as the expected parameter values. The actual parameter values varying from the expected parameter values is undesirable and can cause inefficient operation, undesired volumetric flow, undesired pressures, among other potential issues.
  • Discrepancies between the actual parameter values and the expected parameter values need to be identified to ensure desired outputs from each fan array 12. Discrepancies can arise at any time during the operation of air-handling system 10. For example, individual ones of fan assemblies 18 can be replaced.
  • the motor operating parameters of the replacement fan assembly 18 need to be configured such that the actual operating parameter values of the motor controller 22 in the replacement fan assembly 18 match the expected operating parameter values for the location of that replacement fan assembly 18.
  • control module 14 is configured to determine a parameter status of one or more of fan assemblies 18. While the parameter status determinations are discussed with regard to motor operating parameter values, it is understood that discussion equally applies to a parameter status determination regarding the motor operating parameters themselves. For example, control module 14 can determine whether the motor controller 22 has the correct motor operating parameters in addition or alternatively to determining a parameter status based on the values of the operating parameters that are stored in the motor controller 22. Control module 14 can be configured to determine the parameter status for multiple fan assemblies 18 associated with control module 14. For example, control module 14 can be configured to determine the parameter statuses of up to all of the fan assemblies 18 of a fan array 12.
  • Control module 14 can be configured to determine a parameter status for fan assemblies 18 across multiple ones of fan arrays 12, such as in examples where control module 14 is operatively associated with more than one fan array 12. For example, control module 14 can be configured to determine the parameter status of each fan assembly 18 in each fan array 12 associated with control module 14.
  • Control module 14 initiates a parameter status determination for a target fan assembly 18 by generating a parameter status inquiry and sending the parameter status inquiry to a target motor controller 22.
  • the motor controller 22 provides the actual operating parameter values for that motor controller 22 to control module 14.
  • Control module 14 compares the actual operating parameter values for that motor controller 22 to the expected operating parameter values for that motor controller 22. For example, control module 14 can recall the expected operating parameter values from a memory of control module 14. Control module 14 can recall the expected operating parameter values based on an address of the motor controller 22 within the communications network. The expected operating parameter values are thus associated with a location within air-handling system 10 rather than with a particular motor controller 22.
  • the control module 14 compares the actual operating parameter values with the expected operating parameter values to determine if a variation exists.
  • the parameter status determination can be one of a valid status and an invalid status.
  • control module 14 is configured such that the parameter status determination is binary. For example, any variation between the actual parameter values received from the motor controller 22 and the expected parameter values can result in an invalid status determination.
  • the invalid status can be associated with the fan assembly 18 generally and/or can be associated with the one or more motor parameters that caused the invalid status.
  • a valid status determination is made when the actual operating parameter values match the expected operating parameter values.
  • control module 14 is configured to determine an invalid status based on a determination count threshold. Control module 14 can be configured to determine that an invalid status exists based on the invalid status determination being made multiple times.
  • the determination count threshold can be any desired number of parameter status determinations, such as one, two, three, or more.
  • Control module 14 can store the invalid status in the memory of control module 14 and/or can provide an error notification to the user. Control module 14 can generate and provide the error notification regarding the invalid status to the user via user interface 16. For example, control module 14 can be configured to generate an alert or trigger an alarm based on an invalid status determination being made. Control module 14 can provide the invalid status determination notification when the invalid status determination is made or after a scan is complete, as discussed in more detail below.
  • FIG. 2 shows a method 100 of diagnosing and monitoring fan assemblies in accordance with the present disclosure. The method may be, for example, applied to a control module 14.
  • control module 14 may generate a parameter status inquiry.
  • control module 14 may send the parameter status inquiry to a target motor controller.
  • control module 14 may receive actual operating parameter values for the target motor controller.
  • control module 14 may compare the actual operating parameter values to an expected operating parameter value for the target motor controller and determining a status.
  • control module 14 may store in memory and/or provide a notification of the status.
  • control module 14 may initiate corrective action based on an invalid status determination.
  • Control module 14 can be configured to initiate corrective action based on an invalid status determination. Control module 14 can thus initiate a parameter correction for motor controller 22. Control module 14 can thus reconfigure the parameters of target ones of the motor controllers 22 based on expected parameter values, thus initiating a repair of that unit.
  • control module 14 can generate and provide a reconfiguration prompt to the user, such as via user interface 16, based on the invalid status determination. The reconfiguration prompt can ask the user whether control module 14 should rewrite the motor operating parameter values of the target motor controller 22 to be the expected operating parameter values.
  • the control module 14 can write the expected operating parameter values to the target motor controller 22 based on an affirmative reply from the user. As such, the user can provide a reconfigure command to the control module 14 to cause the control module 14 to update the actual parameter values of the target motor controller 22 based on the expected parameter values.
  • FIG. 3 shows a method 200 of initiating a parameter correction in accordance with the present disclosure.
  • the method may be, for example, applied to a control module 14.
  • step 201 the control module 14 may initiate a parameter correction.
  • step 202 the control module 14 may provide a reconfiguration prompt to a user based on invalid status determination.
  • control module 14 may receive a user command to rewrite the motor operating parameter values.
  • control module 14 may rewrite the motor operating parameter values of the target motor controller to be the expected operating parameter values.
  • control module 14 is configured to autonomously take corrective action for the target motor controller 22.
  • control module 14 can reconfigure motor controller 22 by writing the expected parameter values to the motor controller 22 to replace the erroneous actual parameter values based on control module 14 making an invalid status determination.
  • the control module 14 can be configured to autonomously initiate a repair sequence during which the control module 14 writes the expected parameter value to the motor controller 22 to replace the erroneous actual parameter value.
  • the repair sequence can be autonomously initiated and proceeded through by the control module 14 or can be initiated based on a signal received from a user, among other options. Both the autonomous and user-initiated repair sequences can be considered to be initiated based on a command signal, which is generated by the control module 14 with the autonomous repair sequence and is generated by the user in the user-initiated repair sequence.
  • FIG. 4 shows a method 300 of autonomously initiating a parameter correction in accordance with the present disclosure.
  • the method may be, for example, applied to a control module 14.
  • control module 14 may autonomously initiate a parameter correction.
  • control module 14 may write the expected parameter value to replace the erroneous actual parameter value.
  • Control module 14 can, in some examples, generate and send a supplemental parameter status inquiry to the target motor controller 22.
  • the control module 14 can validate, based on the actual parameter value received from target motor controller 22 in response to the supplemental parameter status inquiry, whether the expected parameter values have been applied to the target motor controller 22.
  • Control module 14 can provide a notification to the user, such as via user interface 16, that the target motor controller 22 has been properly reconfigured.
  • control module 14 can record in its memory the fact that the motor operating parameter values for a motor controller 22 were reconfigured by control module 14.
  • Control module 14 can keep a count of reconfigurations and can provide that information to the user, such as via user interface 16.
  • the actual parameter values can be stored in non-volatile memory of the motor controller 22, which memory can be damaged by writing to the memory too many times. The count assists the user in determining whether to reconfigure the operating parameter values of the target motor controller 22.
  • control module 14 is configured to automatically reconfigured the actual parameter values of the target motor controller 22 based on the count being at or less than a threshold.
  • Control module 14 can be configured to provide the reconfiguration prompt to the user based on the count being at or greater than the threshold.
  • control module 14 can be configured to automatically reconfigure the actual parameter values if it is the first reconfiguration and to not take automatic action if motor controller 22 has previously been configured by control module 14.
  • Control module 14 determining the parameter status for a single motor controller 22 is discussed above.
  • Control module 14 can be configured to determine the parameter statuses of multiple ones of motor controllers 22 across one or more fan arrays 12. For example, control module 14 can be configured to serially determine the parameter status of multiple fan assemblies 18 in a fan array 12 or of fan assemblies 18 in more than one fan array 12. Control module 14 can be configured to serially determine the parameter status of each fan assembly 18 in a first fan array 12 and then each fan assembly 18 in a second fan array 12. During a serial parameter status determination, the control module 14 can determine the parameter statuses of the motor controllers 22 in a stepwise manner.
  • control module 14 can be configured to determine the parameter status of a subset of the motor controllers 22 at any given time before determining the parameter statuses of a next subset of motor controllers 22. In some examples, control module 14 is configured to determine the parameter status of a single motor controller 22 at a given time before determining the parameter status of a next motor controller 22 in the scan order.
  • control module 14 can determine the parameter status of a target motor controller 22. After making that parameter status determination, control module 14 determines the parameter status of the next one of the motor controllers 22. Control module 14 can determine the parameter status of each fan assembly 18 in fan array 12a, then determine the parameter status of each fan assembly 18 in fan array 12b, etc. Control module 14 can continue making parameter status determinations until a parameter status for each fan assembly 18 has been determined.
  • Control module 14 is configured to actively monitor the actual motor operating parameters of fan assemblies 18 to determine the parameter statuses. An example scan process is described in more detail below. In the example scan event, control module 14 is operably associated with fan array 12a, having fan assemblies 18a-18n, and with fan array 12b, assumed to have four fan assemblies 18 as shown in FIG. 1A.
  • Control module 14 initiates the status determination mode to determine the parameter status of each fan assembly 18.
  • Control module 14 knows the communication addresses of the various motor controllers 22 in air-handling system 10.
  • Control module 14 initiates a parameter scan and determines the parameter statuses of the fan assemblies 18 based on a scan order.
  • the scan order begins at the first fan assembly 18 of fan array 12a (e.g., fan assembly 18a) and proceeds through the fan assemblies 18 of fan array 12a to the last fan assembly 18 of fan array 12a (e.g., fan assembly 18n).
  • Next in the scan order is fan array 12b, beginning with the first fan assembly 18 of fan array 12b and ending with the last (e.g., fourth) fan assembly 18 of fan array 12b.
  • Control module 14 generates and sends a parameter inquiry to a first address in the scan order.
  • motor controller 22a of fan assembly 18a is disposed at the first address location.
  • the control module 14 generates and sends a parameter status inquiry to motor controller 22a.
  • Control module 14 receives the actual motor operating parameter values from motor controller 22a and makes the parameter status determination based on those actual motor operating parameter values and based on the expected motor operating parameter values for the location of the first address, which is the location of fan assembly 18a of motor controller 22a within air-handling system 10.
  • control module 14 determines the parameter status of the serially next motor controller 22 in the scan order.
  • Control module 14 generates and sends a parameter inquiry to the second address in the scan order (e.g., the address location of motor controller 22b of fan assembly 18b).
  • Control module 14 receives the actual motor operating parameter values from motor controller 22b and makes the parameter status determination based on those actual motor operating parameter values and based on the expected motor operating parameter values for the location of the fan assembly 18b of motor controller 22b within air-handling system 10.
  • Control module 14 continues to serially generate and send parameter inquiries to the motor controllers 22 of fan array 12a such that a parameter status determination is made for each of the motor controllers 22 of fan array 12a.
  • control module 14 is configured to implement a time delay between sending each parameter status inquiry.
  • control module 14 can be configured to implement a delay of thirty seconds, one minute, two minutes, five minutes, or more between sending inquiries and/or making the parameter status determinations. Implementing the delay frees bandwidth on the communication network of air-handling system 10.
  • control module 14 can determine the parameter statuses of the motor controllers 22 in the serially next fan array 12 in the scan order (e.g., fan array 12b in the example discussed). Control module 14 generates and sends a parameter status inquiry to the first motor controller 22 of fan array 12b according to the scan order and determines the status of that first motor controller 22 based on the actual motor operating parameter values received from that first motor controller 22 and based on the expected motor operating parameter values for that first motor controller 22. Control module 14 continues to determine the parameter status for each motor controller 22 of fan array 12b.
  • control module 14 is described as making parameter status determinations for fan array 12a before making parameter status determinations for fan array 12b, it is understood that the scan order can be any desired order.
  • the scan order can include a fan assembly 18 from fan array 12b at a location in the scan order between two fan assemblies 18 of fan array 12a.
  • the scan order can be based on a parameter type.
  • control module 14 can send a parameter inquiry regarding a first parameter to the various fan assemblies 18 to determine a status of that first parameter. The control module 14 can then determine the status of a second parameter. As such, the control module 14 can, in some examples, make a parameter status determination for a first parameter, then a status determination for a second parameter, etc. for each of the motor operating parameters.
  • the expected motor operating parameter values can vary between the motor controllers 22 of different fan arrays 12 and between the motor controllers 22 within a fan array 12.
  • the expected motor operating parameter values can be associated with the various fan assembly 18 addresses throughout air-handling system 10 and stored in the memory of control module 14.
  • Control module 14 can individually recall the expected motor operating parameter values for each motor controller 22 from the memory of control module 14 based on the address that the parameter status inquiry was sent to or that a reply to the parameter status inquiry was received from.
  • control module 14 can recall a single set of expected motor operating parameter values for that fan array 12 (e.g., an array operating parameter values) and utilize that information as the expected motor operating parameter values for the parameter status determination.
  • control module 14 can provide an error notification and/or initiate corrective action for any misconfigured motor controllers 22.
  • Control module 14 can be configured to provide the error notification and/or initiate corrective action at the time an invalid status is determined (e.g., mid-scan), after the scan is complete, based on an invalid status count threshold, and/or at any other time during operation. For example, if control module 14 determines that motor controller 22d of fan array 12a has an invalid status, then control module 14 can generate and provide the error notification to the user when the invalid status is determined or after the scan is complete. In some examples, there may be a delay in receiving a response form the user. Control module 14 can continue the scan and make parameter status determinations for other motor controllers 22. Control module 14 can be configured to reconfigure the motor controller 22 having the invalid status determination when the reconfiguration command is received (e.g., from the user), regardless of the actual target motor controller 22 that control module 14 is scanning at that time.
  • control module 14 can determine that the error exists and provide the error notification and/or initiate corrective action based on the invalid status count threshold. Control module 14 can thereby require one or more invalid statuses before determining that the error actually exists. For example, if the invalid status count threshold is two, then control module 14 will provide the error notification and/or initiate corrective action once two invalid status determinations have been made for a fan assembly 18. It is understood that the invalid status count threshold can be any desired number of invalid statuses, such as one, two, three, four, or more. The multiple invalid statuses can be determined across multiple scans and/or control module 14 can repeat the parameter status determination based on an initial invalid status determination.
  • control module 14 can immediately reinitiate the parameter status determination for that fan assembly 18.
  • control module 14 stores the invalid status determination in memory and continues with the scan.
  • the multiple invalid status determinations when the invalid status threshold count is more than one, counteract nuisance notifications and assist in ensuring that the error is a true error before taking corrective action.
  • Control module 14 can be configured to operate in a repeating scan mode during which the control module 14 automatically repeats the parameter status scan. For example, after completing the parameter determination process for fan array 12a and then fan array 12b, control module 14 can restart the scan at the first target motor controller 22 in the scan sequence (e.g., motor controller 22a in the example discussed). In some examples, control module 14 can immediately restart the scan process after completing a previous scan, such that control module 14 operates in a continuous scan mode. In some examples, control module 14 can implement a delay between subsequent scans, such that control module 14 operates in a periodic scan mode. For example, control module 14 can be configured to implement one scan per scan period, which scan period can be one day, one week, one month, etc.
  • the parameter status determination process and system provide significant advantages.
  • a user is required to connect to each motor controller 22 in the air handling system 10 to determine the parameter statuses, which can include hundreds or thousands of fan assemblies 18 and motor controllers 22.
  • the user can be required to wire into each motor controller 22 to determine the parameter status of that motor controller 22, or the user can wirelessly connect to the individual fan assemblies 18.
  • such connections can be prone to errors due to the large number of fan assemblies 18 (e.g., the user may be connected to a different fan assembly 18 than expected or may have incorrect expected operating parameters for the target motor controller 22).
  • Control module 14 determines the parameter status of the motor controllers 22, thereby quickly and efficiently determining statuses and identifying errors, reducing costs, and reducing time committed to monitoring the motor operating parameters. Control module 14 automatically repeating the scan process, continuously or periodically, identifies errors that arise due to a faulty motor controller 22 or due to replacement of a fan assembly 18. For example, motor controller 22b can have a valid status during a first scan and then the fan assembly 18b could be replaced with a new fan assembly 18b having incorrect motor operating parameters. Control module 14 will identify such errors on subsequent scans. Control module 14 can take corrective action when incorrect motor operating parameters are identified, quickly and efficiently alerting the user to any errors and correcting those errors, thereby reducing the prevalence and residence time of system errors, increasing system efficiency, and increasing user confidence. Control module 14 can automatically write the expected motor operating parameters to a motor controller 22 in response to an invalid status, minimizing the time that errors are present and increasing system efficiency.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Positive-Displacement Air Blowers (AREA)

Abstract

Un système de traitement d'air comprend un ou plusieurs réseaux de ventilateurs qui comprennent chacun une pluralité d'ensembles ventilateurs. Chaque ensemble ventilateur comprend un moteur relié de manière fonctionnelle à un impulseur, et un dispositif de commande de moteur relié de manière fonctionnelle au moteur. Un module de commande est relié de manière fonctionnelle aux dispositifs de commande de moteur et est configuré pour déterminer un état des paramètres de fonctionnement de chaque dispositif de commande de moteur sur la base d'informations de valeur de paramètre réelles reçues en provenance du dispositif de commande de moteur et d'informations de valeur de paramètre attendues.
PCT/US2022/021516 2021-03-24 2022-03-23 Système et procédé de diagnostic et de surveillance de réseaux de ventilateurs WO2022204262A1 (fr)

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CA3232443A CA3232443A1 (fr) 2021-03-24 2022-03-23 Systeme et procede de diagnostic et de surveillance de reseaux de ventilateurs

Applications Claiming Priority (4)

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US202163165432P 2021-03-24 2021-03-24
US63/165,432 2021-03-24
US17/685,976 US20220307712A1 (en) 2021-03-24 2022-03-03 Fan array diagnostic and monitoring system and method
US17/685,976 2022-03-03

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10138901B2 (en) * 2011-03-21 2018-11-27 Nortek Air Solutions, Llc Systems and methods for implementing a fan array with quick connect and modular control
WO2020054525A1 (fr) * 2018-09-13 2020-03-19 ミネベアミツミ株式会社 Dispositif de soufflage
US20210003302A1 (en) * 2018-03-26 2021-01-07 Panasonic Intellectual Property Management Co., Ltd. Ventilation control device and ventilation system

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10138901B2 (en) * 2011-03-21 2018-11-27 Nortek Air Solutions, Llc Systems and methods for implementing a fan array with quick connect and modular control
US20210003302A1 (en) * 2018-03-26 2021-01-07 Panasonic Intellectual Property Management Co., Ltd. Ventilation control device and ventilation system
WO2020054525A1 (fr) * 2018-09-13 2020-03-19 ミネベアミツミ株式会社 Dispositif de soufflage

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