Integrated control and fault detection of HVAC equipment

• US 6,223,544 B1
• Filed: 08/05/1999
• Issued: 05/01/2001
• Est. Priority Date: 08/05/1999
• Status: Expired due to Term

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Seem, John E
• Primary Examiner(s): Tanner, Harry B.
• Application Number:
  US09/368,972
• Time in Patent Office: 635 Days
• Field of Search: 62/125, 62/126, 62/127, 62/129, 62/130, 236/94, 165/11.1
• US Class Current: 62/127
• 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 11/32 Responding to malfunctions or emergencies
• CPC Class Codes: F24F 11/38 Failure diagnosis

Abstract

Fault detection is implemented on a finite state machine controller for an air handling system. The method employs data, regarding the system performance in the current state and upon a transition occurring, to determine whether a fault condition exists. The fault detection may be based on saturation of the system control or on a comparison of actual performance to a mathematical model of the air handling system. As a consequence, the control does not have to be in steady-state operation to perform fault detection.

Claims

1. In a finite state machine controller for a heating, ventilating and air conditioning (HVAC) system for a building, wherein the state machine controller has a plurality of states and makes transitions between states upon the occurrence of predefined conditions, a fault detection method comprising:

gathering operational data regarding performance of the HVAC system;

evaluating the operational data against predefined criteria for a current state in which the finite state machine controller is operating or for a given transition which has occurred; and

based on the evaluating step determining whether an fault condition exists.

2. The method as recited in claim 1 wherein the predefined criteria indicates that control of the HVAC system has become saturated in the current state.

3. The method as recited in claim 1 wherein the predefined criteria indicates that control of the HVAC system has become saturated in the current state and saturation can not be overcome by a transition to another state.

4. The method as recited in claim 1 wherein evaluating the operational data is performed when a predetermined transition occurs between states and comprises comparing the performance of the HVAC system to a mathematical system model of the HVAC system.

5. The method as recited in claim 1 wherein evaluating the operational data is performed when a predetermined transition occurs between states and comprises:

comparing the performance of the HVAC system to a mathematical system model of the HVAC system to derive a residual; and

declaring a fault condition in response to the residual.

6. The method as recited in claim 5 wherein the residual has a numerical value and the fault condition is declared in response to the magnitude of the numerical value.

7. The method as recited in claim 5 wherein the fault condition is declared in response to detecting a predefined change in the residual.

8. The method as recited in claim 5 wherein the fault condition is declared in response to detecting an abrupt change in the residual.

9. The method as recited in claim 5 wherein the residual is a function of at least two of a temperature of air outside the building, a temperature of air supplied by the HVAC system, temperature of air returned to the HVAC system from a room of the building, and a temperature of a mixture of air from outside the building and the air returned to the HVAC system.

10. The method as recited in claim 5 wherein the residual is derived from a mass balance for dry air entering and leaving a space of the building controlled by the HVAC system.

11. The method as recited in claim 5 wherein the residual is a function of a fraction of outdoor air utilized by the HVAC system.

12. The method as recited in claim 5 wherein the residual is derived from an energy balance for air entering and leaving the HVAC system.

13. In a finite state machine controller for a heating, ventilating and air conditioning (HVAC) system for a building, wherein the state machine controller has a plurality of states and makes transitions between states upon the occurrence of predefined conditions, a fault detection method comprising:

gathering operational data regarding performance of the HVAC system in the given state;

detecting when control of the HVAC system becomes saturated in a given state wherein such saturation can not be overcome by a transition to another state; and

issuing a signal that indicates an occurrence of a fault condition.

14. The method as recited in claim 13 further comprising issuing an indication of possible causes of the fault condition.

15. In a finite state machine controller for a heating, ventilating and air conditioning (HVAC) system for a building, wherein the state machine controller has a plurality of states and makes transitions between states when predefined conditions exist, a fault detection method comprising:

gathering operational data regarding performance of the HVAC system in the given state;

occasionally comparing performance of the HVAC system to a model of HVAC system performance; and

declaring a fault condition in response to results of the comparing.

16. The method as recited in claim 15 wherein the step of occasionally comparing is performed in response to a transition occurring.

17. The method as recited in claim 15 wherein the occasionally comparing produces a residual;

and the fault condition is declared in response to a value of the residual.

18. The method as recited in claim 17 wherein the fault condition is declared in response to detecting a predefined change in the residual.

19. The method as recited in claim 17 wherein the fault condition is declared in response to detecting an abrupt change in the residual.

20. The method as recited in claim 17 wherein the residual is a function of at least two of a temperature of air outside the building, a temperature of air supplied by the HVAC system, temperature of air returned to the HVAC system from a room of the building, and a temperature of a mixture of air from outside the building and the air returned to the HVAC system.

21. The method as recited in claim 17 wherein the residual is derived from a mass balance for dry air entering and leaving a space of the building controlled by the HVAC system.

22. The method as recited in claim 17 wherein the residual is a function of a fraction of outdoor air utilized by the HVAC system.

23. The method as recited in claim 17 wherein the residual is derived from an energy balance for air entering and leaving the HVAC system.

24. The method as recited in claim 15 further comprising providing an indication of possible causes of the fault condition.