LOAD CONTROL SYSTEM AND METHOD FOR REGULATING POWER SUPPLY TO A THERMOSTAT

• US 20180038607A1
• Filed: 08/04/2016
• Published: 02/08/2018
• Est. Priority Date: 08/04/2016
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Johnson, Justin Bruce, Slingsby, Karl Andrew, Masters, Timothy Daniel, Brager, Ryan F.
• Granted Patent: US 10,295,212 B2
• Time in Patent Office: Days
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/37 Resuming operation, e.g. after power outages; Emergency starting
• CPC Class Codes: F24F 11/46 Improving electric energy efficiency or saving
• CPC Class Codes: F24F 11/58 using Internet communication
• CPC Class Codes: F24F 11/61 using timers
• CPC Class Codes: F24F 11/62 characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
• CPC Class Codes: F24F 2110/00 Control inputs relating to air properties
• CPC Class Codes: F24F 2140/50 Load
• CPC Class Codes: F24F 2140/60 Energy consumption
• CPC Class Codes: G05B 2219/2614 HVAC, heating, ventillation, climate control
• CPC Class Codes: G05D 23/19 characterised by the use of electric means G05D23/1393 takes precedence
• CPC Class Codes: G05D 23/1905 associated with tele control

Abstract

A system for controlling a load control relay (LCR) supplying power to a thermostat of a heating, ventilating, and air conditioning (HVAC) system includes a controller programmed to maximize the amount of time that a load of the HVAC system may receive power. The controller operates by measuring a thermostat delay time of the thermostat and modifying cycle shed and restore times for controlling the LCR based on the measured thermostat delay time. By controlling the LCR according to the modified cycle shed and restore times, the controller compensates for the thermostat delay time, and the load is able to be active for a longer period of time than it otherwise would be when operating under demand-response controls.

Claims

1. A system for controlling a load control relay (LCR) for a heating, ventilating, and air conditioning (HVAC) system, the system comprising a controller programmed to:

measure a thermostat delay time of a thermostat of the HVAC system, the thermostat delay time comprising an amount of time between restoring the LCR and receiving power in a load control line coupled between the thermostat and a load of the HVAC system;

calculate a new cycle shed time and a new cycle restore time based on the measured thermostat delay time, wherein the new cycle shed time and the new cycle restore time compensate for the thermostat delay time; and

control the LCR according to the new cycle shed time and new cycle restore time.

2. The system of claim 1 wherein the controller is further programmed to:

receive a control command for controlling the LCR, the control command comprising a shed percentage and one of a cycle period and a control duration;

if the control command includes a control duration, determine a cycle period based on the control duration;

calculate an initial cycle shed time and an initial cycle restore time based on the cycle period and the shed percentage; and

measure the thermostat delay time during the initial cycle restore time.

3. The system of claim 2 wherein, if the initial cycle shed time is greater than an average thermostat delay time, the controller is programmed to:

calculate the new cycle shed time by subtracting the average thermostat delay time from the initial cycle shed time; and

calculate the new cycle restore time by adding the average thermostat delay time to the initial cycle restore time.

4. The system of claim 3 wherein, if the initial cycle shed time is less than or equal to the average thermostat delay time, the controller is programmed to:

set the new cycle shed time to a predefined cycle shed time; and

set the new cycle restore time to the cycle period minus the predefined cycle shed time.

5. The system of claim 1 wherein the controller is programmed to sense the thermostat delay time of the thermostat by:

starting a thermostat delay timer simultaneously with restoring the LCR;

sensing if the load control line is active; and

if the load control line is active, stopping the thermostat delay timer.

6. The system of claim 5 wherein the controller is further programmed to sense the thermostat delay time of the thermostat by:

if the load control line is not active;

determining whether any time remains in a current cycle for controlling the LCR;

if time remains in the current cycle, continuing to sense if the load control line is active; and

if no time remains in the current cycle;

ceasing to sense if the load control line is active;

determining if any cycles remain in a current control command for controlling the LCR;

if cycles remain in the current control command, continue controlling the LCR; and

if no cycles remain in the current control command, ceasing to control the LCR.

7. The system of claim 1 wherein, if the thermostat delay time is greater than a maximum control adjustment time, the controller is programmed to calculate the new cycle shed time and the new cycle restore time based on an existing average thermostat delay time, the existing average thermostat delay time comprising an average amount of time between restoring the LCR and receiving power in the load control line previous to the thermostat delay time.

8. The system of claim 1 wherein the controller is further programmed to:

store the thermostat delay time as part of an average thermostat delay time; and

calculate the new cycle shed time and the new cycle restore time based on the average thermostat delay time.

9. The system of claim 8 wherein the controller is programmed to store the thermostat delay time as part of the average thermostat delay time by:

temporarily storing an existing average thermostat delay time;

calculating a potential average thermostat delay time based on the existing average thermostat delay time and the thermostat delay time;

if the potential average thermostat delay time is within a time threshold different from the existing average thermostat delay time, setting the average thermostat delay time to the potential average thermostat delay time; and

if the potential average thermostat delay time is different from the existing average thermostat delay time by an amount of time beyond the time threshold, setting the average thermostat delay time to one of the existing average thermostat delay time minus the time threshold and the existing average thermostat delay time plus the time threshold.

10. A method of controlling a load control relay (LCR) for a heating, ventilating, and air conditioning (HVAC) system having a thermostat and a load control line coupling the thermostat to a load, the method comprising:

measuring a thermostat-induced delay between a time the LCR is restored and a time power is received on the load control line;

defining a compensation time to offset the thermostat-induced delay;

calculating a new cycle shed time and a new cycle restore time based on the compensation time; and

controlling the LCR according to the new cycle shed time and the new cycle restore time.

11. The method of claim 10 wherein defining the compensation time comprises:

storing an existing average thermostat-induced delay between a time the LCR is restored and a time power is received on the load control line;

calculating a potential compensation time based on the thermostat-induced delay and the existing average thermostat-induced delay;

if the potential compensation time is within a time threshold of the existing average thermostat-induced delay, setting the compensation time to the potential compensation time;

if the potential compensation time exceeds the existing average thermostat-induced delay by more than the time threshold, setting the compensation time to the existing average thermostat-induced delay plus the time threshold; and

if the potential compensation time is below the existing average thermostat-induced delay by more than the time threshold, setting the compensation time to the existing average thermostat-induced delay minus the time threshold.

12. The method of claim 11 further comprising calculating the potential compensation time as a weighted average of the thermostat-induced delay and the existing average thermostat-induced delay.

13. The method of claim 10 wherein calculating the new cycle shed time comprises subtracting the compensation time from an initial cycle shed time of a control command for controlling the LCR;

and

wherein calculating the new cycle restore time comprises adding the compensation time to an initial cycle restore time of the control command.

14. The method of claim 10 further comprising comparing the thermostat-induced delay to a maximum control adjustment time;

and

wherein, if the thermostat-induced delay is greater than the maximum control adjustment time, defining the compensation time comprises setting the compensation time to an existing average thermostat-induced delay, the existing average thermostat-induced delay comprising a time between when the LCR is restored and power is received on the load control line.

15. The method of claim 10 further comprising ceasing control of the LCR if the load control line stays inactive for a predetermined time, no time remains in a cycle period of a current cycle for controlling the LCR, and no cycles remain in a control command for controlling the LCR.

16. A load control system for selectively supplying power to a thermostat of a heating, ventilating, and air conditioning (HVAC) system, the load control system comprising:

a load control relay (LCR) coupleable to the HVAC system;

a sensor configured to sense whether a load control line for a load of the HVAC system is active;

a communication system capable of communicating with a master station to receive a control command comprising a shed percentage and one of a control duration and a cycle period for controlling the LCR; and

a controller for selectively controlling the LCR according to the control command, the controller programmed to;

calculate a cycle shed time and a cycle restore time based on the control command;

control the LCR according to the cycle shed time and the cycle restore time;

determine a thermostat delay between a restore time of the LCR and a time the sensor senses that the load control line is active;

modify the cycle shed time and the cycle restore time based on the thermostat delay to counteract the thermostat delay; and

control the LCR according to the modified cycle shed time and the modified cycle restore time.

17. The load control system of claim 16 wherein the controller determines the thermostat delay by:

starting a timer upon restoring the LCR; and

stopping the timer when the sensor senses a current on the load control line.

18. The load control system of claim 16 further programmed to calculate an average thermostat delay based on the thermostat delay;

and

modify the cycle shed and restore times based on the average thermostat delay.

19. The load control system of claim 18 wherein the controller is further programmed to calculate the average thermostat delay as a weighted average of an existing average thermostat delay and the thermostat delay.

20. The load control system of claim 19 wherein the controller is programmed to modify the average thermostat delay based on a comparison to the existing average thermostat delay.