Monitoring air filter status in automotive HVAC system

• US 9,120,366 B2
• Filed: 04/27/2012
• Issued: 09/01/2015
• Est. Priority Date: 04/27/2012
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Hoke, Paul B., Johnston, William S., Hurd, James R.
• Primary Examiner(s): McAllister, Steven B
• Assistant Examiner(s): Hamilton, Frances F
• Application Number:
  US13/457,542
• Publication Number:
  US 20130288585A1
• Time in Patent Office: 1,222 Days
• Field of Search: 454/75, 340/607
• US Class Current: 1/1
• CPC Class Codes: B60H 2003/0683 the quality of the filter or the air being checked
• CPC Class Codes: B60H 3/0616 with provisions for replacing the filter element

Abstract

A system and methods are provided for monitoring for a clogged or unclogged state of an air filter in an automotive HVAC system. The HVAC system includes a blower having a blower motor providing a driven airflow. A plurality of outlet registers is controllable to provide a plurality of circulation modes. An evaporator selectably cools the driven airflow, and the air filter passes the driven airflow. The method enters a baseline condition, wherein the baseline condition includes applying a moisture purge to the evaporator and selection of a predetermined circulation mode. The blower motor is controlled to maintain a testing speed. An energization of the blower motor is quantified while maintaining the testing speed. The energization is compared to a base value derived according to the baseline condition with the air filter in an unclogged state. A replacement action is triggered when the energization is greater than the base value.

Claims

1. A method of monitoring for a clogged or an unclogged state of an air filter in an automotive HVAC system, wherein the HVAC system includes a blower having a blower motor providing a driven airflow, a plurality of outlet registers controllable to provide a plurality of circulation modes, and an evaporator for selectably cooling the driven airflow, wherein the air filter passes the driven airflow, the method comprising the steps of:

entering a baseline condition, wherein the baseline condition includes applying a moisture purge to the evaporator and selection of a predetermined circulation mode;

controlling the blower motor to maintain a testing speed;

quantifying an energization of the blower motor while maintaining the testing speed;

comparing the energization to a base value derived according to the baseline condition with the air filter in an unclogged state;

triggering a replacement action when the energization is greater than the base value; and

wherein the method of monitoring of the air filter is performed in a plurality of baseline conditions each corresponding to a respective circulation mode, wherein a plurality of base values are stored according to respective baseline conditions, and wherein the method further comprises the step of selecting a base value for use in the comparing step according to the predetermined circulation mode present in the HVAC system.

2. The method of claim 1 wherein the HVAC system further includes inlets for selecting a fresh mode or a recirculation mode, and wherein the baseline condition further includes selection of either the fresh mode or the circulation mode.

3. The method of claim 1 wherein the energization is comprised of a motor torque.

4. The method of claim 1 wherein the energization is comprised of a motor current.

5. The method of claim 1 wherein the baseline condition is automatically entered by the HVAC system, and wherein the predetermined circulation mode is comprised of a floor mode.

6. The method of claim 5 wherein the predetermined circulation mode is further comprised of a recirculation mode.

7. The method of claim 1 wherein the moisture purge is comprised of a blowoff operation of the blower.

8. The method of claim 1 wherein the testing speed is automatically selected by the HVAC system.

9. The method of claim 1 wherein the testing speed is manually set.

10. The method of claim 1 further comprising the steps of:

detecting a replacing of the air filter; and

recalibrating the base value in response to detecting the replacement.

11. The method of claim 1 wherein the replacement action is comprised of a human perceptible signal.

12. An HVAC system for an automotive vehicle, comprising:

a blower having a blower motor providing a driven airflow;

a plurality of outlet registers controllable to provide a plurality of circulation modes;

an evaporator for selectably cooling the driven airflow;

an air filter for passing the driven airflow;

a controller configured to monitor for a clogged or an unclogged state of the air filter by performing the steps of;

entering a baseline condition, wherein the baseline condition includes applying a moisture purge to the evaporator and selection of a predetermined circulation mode;

controlling the blower motor to maintain a testing speed;

quantifying an energization of the blower motor while maintaining the testing speed;

comparing the energization to a base value derived according to the baseline condition with the air filter in an unclogged state;

triggering a replacement action when the energization is greater than the base value; and

monitoring the air filter in a plurality of baseline conditions each corresponding to a respective circulation mode, wherein the controller stores a plurality of base values according to respective baseline conditions, and wherein the controller selects a base value for use in the comparing step according to the predetermined circulation mode present in the HVAC system.

13. The HVAC system of claim 12 further comprising inlets for selecting a fresh mode or a recirculation mode, wherein the baseline condition further includes selection of either the fresh mode or the circulation mode.

14. The HVAC system of claim 12 wherein the energization is comprised of a motor torque.

15. The HVAC system of claim 12 wherein the energization is comprised of a motor current.

16. The HVAC system of claim 12 wherein the baseline condition is automatically entered by the controller, and wherein the predetermined circulation mode is comprised of a floor mode.

17. The HVAC system of claim 16 wherein the predetermined circulation mode is further comprised of a recirculation mode.

18. The HVAC system of claim 12 wherein the moisture purge is comprised of a blowoff operation of the blower.

19. The HVAC system of claim 12 further comprising an interface for providing a human perceptible signal as the replacement action.

20. The HVAC system of claim 12 wherein the controller further performs the steps of:

detecting a replacing of the air filter; and

recalibrating the base value in response to detecting the replacement.

21. A method of monitoring for a clogged or an unclogged state of an air filter in an automotive HVAC system, wherein the HVAC system includes a blower having a blower motor providing a driven airflow, a plurality of outlet registers controllable to provide a plurality of circulation modes, and an evaporator for selectably cooling the driven airflow, wherein the air filter passes the driven airflow, the method comprising the steps of:

a) entering a baseline condition, wherein the baseline condition includes applying a moisture purge to the evaporator and selection of a predetermined circulation mode;

b) controlling the blower motor to maintain a testing speed;

c) quantifying an energization of the blower motor while maintaining the testing speed;

d) comparing the energization to a base value derived according to the baseline condition with the air filter in an unclogged state to obtain a comparison value;

e) repeating steps a, b, c, and d to obtain at least one subsequent comparison value;

f) triggering a replacement action when the comparison value and the at least one subsequent comparison value indicates the energization is greater than the base value; and

wherein the method of monitoring the air filter is performed in a plurality of baseline conditions each corresponding to a respective circulation mode, wherein a plurality of base values are stored according to respective baseline conditions, and wherein the method further comprises the step of selecting a base value for use in the comparing step according to the predetermined circulation mode present in the HVAC system.

22. The method of claim 21 wherein at least four subsequent comparison values are obtained;

and triggering a replacement action when the comparison value and the at least four comparison values indicate the energization is greater than the base value.