Technique for detecting and predicting air filter condition

• US 20050247194A1
• Filed: 05/06/2004
• Published: 11/10/2005
• Est. Priority Date: 05/06/2004
• Status: Active Grant

• Current Assignee: Carrier Corporation (Carrier Global Corporation)
• Original Assignee: Carrier Corporation (Carrier Global Corporation)
• Inventors: Finn, Alan M., Kang, Pengju, Sadegh, Payman, Farzad, Mohsen, Stricevic, Slaven
• Granted Patent: US 7,261,762 B2
• Time in Patent Office: Days
• US Class Current: 95/19
• CPC Class Codes: B01D 2273/30 Means for generating a circulation of a fluid in a filtration system, e.g. using a pump or a fan
• CPC Class Codes: B01D 46/0086 Filter condition indicators
• CPC Class Codes: B01D 46/444 by flow measuring
• CPC Class Codes: Y10S 116/25 Air filter condition indicator

Abstract

A method and system for detecting and predicting air filter condition for an air handling system operates by determining a system resistance to air flow. The system resistance is utilized to determine a detection statistic indicative of current filter condition and to predict remaining life of the air filter. The system resistance is determined using models that approximate the expected operation of the air handling system. The approximation is then compared to actual values to obtain a difference. Once the difference between the approximated value exceeds a threshold value, an alarm is initiated that is indicative of system resistance. The remaining air filter life is then determined by using historically gathered data, or by using a known degradation rate of the air filter. Once the remaining life of the air filter is estimated, replacement can be scheduled that would coincide with other maintenance.

Claims

1. A method of detecting air filter clogging for an air handling system comprising the steps of:

a) determining a system resistance;

b) comparing said determined system resistance to a threshold value; and

c) determining that the air filter is plugged in response to said determined system resistance being greater than a threshold value.

2. The method as recited in claim 1, wherein said step a) comprises determining the system resistance utilizing a power and speed of a fan.

3. The method as recited in claim 1, wherein said step a) comprises detecting a power used by a fan, and a speed of the fan.

4. The method as recited in claim 3, wherein said step a) comprises determining a flow rate through the filter.

5. The method as recited in claim 4, wherein said step a) comprises determining a pressure difference across the air filter.

6. The method as recited in claim 5, wherein said step a) comprises determining the filter resistance utilizing said determined pressure differential and flow rate.

7. The method as recited in claim 1, wherein said step a) comprises determining an estimated system resistance utilizing data gathered indicative of current operating conditions.

8. The method as recited in claim 7, wherein said data comprises pressure, temperature, fan speed, and expansion valve actuation.

9. The method as recited in claim 7, wherein said step a) comprises

calculating enthalpy at an inlet and outlet of a heat exchanger;

obtaining refrigerant flow rate;

determining heat exchange rate of the heat exchanger utilizing the refrigerant flow rate and the calculated enthalpies at the inlet and outlet of the heat exchanger;

determining an airflow required to provide the determined heat exchange rate; and

determining system resistance utilizing predetermined fan speed value and said determined airflow.

10. The method as recited in claim 9, comprising the step of calculating a detection statistic value.

11. The method as recited in claim 10, wherein said step b) comprises the step of comparing said calculated detection statistic value to a threshold value and indicating that the air filter is clogged in response to said calculated detection statistic value exceeding said threshold value.

12. The method as recited in claim 1, comprising detecting the system resistance immediately after installation of an unclogged air filter, and determining a condition of heat exchanger fins based upon several detected system resistance values immediately following installation of an unclogged air filter.

13. The method as recited in claim 12, comprising comparing several values of system resistance following installation of an unclogged air filter, and determining that the heat exchanger fin is fouled responsive to the system resistance following installation of an unclogged air filter exceeding a predetermined threshold value

14. A method of predicting air filter clogging for a heating, ventilating and air conditioning system comprising the steps of:

a) determining a system resistance value;

b) calculating a detection statistic value utilizing said determined filter resistance value;

c) comparing said detection statistic value with a threshold value and indicating an alarm based on said comparison; and

d) predicting a time for air filter replacement based on said detection statistic.

15. The method as recited in claim 14, comprising indicating an alarm based on a desired number of consecutive calculated detection statistic values being greater than said threshold value.

16. The method as recited in claim 14, wherein said detection statistic is determined according to the equation:

R_n=max(0, R_n-1+c_n−

μ

)

where

R=the detection statistic;

c=system resistance;

n=sampling interval; and

μ

=the reference mean value of filter resistance.

17. The method as recited in claim 15, comprising predicting remaining time of the air filter in response to said alarm.

18. The method as recited in claim 14, comprising calculating a plurality of said detection statistic values over time and predicting the remaining air filter life based on said plurality of detection statistic values.

19. The method as recited in claim 18, comprising the steps of formulating a model simulating degradation of the air filter, estimating model parameters using historic data, and projecting a remaining life of the air filter using the model simulating degradation of the air filter.

20. The method as recited in claim 19, comprising a statistical model of air filter degradation.

21. The method as recited in claim 20, wherein said statistical model comprises a statistical model of air filter degradation and a finite state model of the degradation process.

22. The method as recited in claim 20, wherein said statistical model comprises probability distributions of a time between changes in air filter degradation, a time of the air filter degradation and a magnitude of each air filter degradation change.

23. The method as recited in claim 22, wherein said step of projecting the remaining life of the air filter comprises calculating a multiple probability distributions of the remaining life utilizing the model simulating degradation of the air filter to obtain a desired confidence level.

24. A system for monitoring an air handling system comprising:

a controller for receiving data indicative of a system resistance of the air handling system, comparing the system resistance to a threshold value, and determining that an air filter of the air handling system is plugged in response to the system resistance being greater than said threshold value.

25. The system as recited in claim 24, wherein said controller receives information indicative of power and speed of a fan for determining the system resistance.

26. The system as recited in claim 25, wherein the power and speed of the fan are utilized to determine a pressure differential across said air filter.

27. The system as recited in claim 24, wherein said controller receives information indicative of current air handling system operating conditions.

28. The system as recited in claim 27, wherein said controller utilizes said information indicative of air handling system operating conditions to determine a heat exchange rate and a rate of airflow required to provide the determined heat exchange rate.

29. The system as recited in claim 24, comprising a plurality of sensors providing data indicative of air handling system operation.

30. The system as recited in claim 24, wherein said controller predicts a future value of said system resistance based on a statistical model of said system resistance.

31. The system as recited in claim 24, wherein said controller predicts a future value of said system resistance based on a finite state model.

32. The system as recited in claim 24, wherein said controller is separate from a controller of the air handling system.

33. The system as recited in claim 24, wherein said controller is an integral portion of a controller for the air handling system.