Dynamic determination of fan speeds

• US 9,702,577 B1
• Filed: 06/24/2015
• Issued: 07/11/2017
• Est. Priority Date: 06/24/2015
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: Lachapelle, Alan Joseph, Phillips, Matthew Thomas, Patrick, Shawn Duane, Greer, Michael Steven, Abdul Salam, Taslim A.
• Primary Examiner(s): Minskey, Jacob T
• Assistant Examiner(s): Pham, Minh-Chau
• Application Number:
  US14/749,515
• Time in Patent Office: 748 Days
• Field of Search: 55471, 55472, 55473, 55DIG 34, 95 1, 95 25, 95 26, 96417, 96397
• CPC Class Codes: B01D 46/446 by pressure measuring
• CPC Class Codes: F24F 11/0001 for ventilation F24F11/30 takes precedence
• 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 11/39 Monitoring filter performance
• 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 11/64 using pre-stored data
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 2110/00 Control inputs relating to air properties
• CPC Class Codes: F24F 2110/40 Pressure, e.g. wind pressure
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

An updated operating speed for a fan of an air handler may be determined. The updated operating speed may depend on a target output volume for the air handler and an intermediate resistance value for a filter of the air handler. The intermediate resistance value may be determined by instructing the fan to operate at a first operating speed for a fixed period of time. During the fixed period of time, a pressure sensing system may sense an observed differential pressure measured across the filter. The observed differential pressure may correspond to the intermediate resistance value. The intermediate resistance value may be used to identify, from a set of filter loading values which may be retained in a filter loading data structure, the updated operating speed for the fan such that the air handler is capable of achieving the target output volume.

Claims

1. A system comprising:

an air handler comprising;

a fan disposed within the air handler;

a filter medium configured to at least filter air that flows into the fan or out of the fan; and

a pressure sensing system configured to at least measure differential pressure across the filter medium; and

a management device in communication with the fan, the management device configured with at least a memory and a processor configured to;

access a target output volume for the air handler, an initial resistance value of the filter medium in a clean condition representing a differential pressure across the filter medium when in the clean condition, and an initial operating speed for the fan such that the air handler achieves the target output volume as air flows through the filter medium in the clean condition;

access a final resistance value of the filter medium in a dirty condition, the dirty condition representing a clogged condition of the filter medium when particles are captured in the filter medium causing the final resistance value to represent a differential pressure across the filter medium that is higher than the initial resistance value;

determine a final operating speed for the fan where the air handler achieves the target output volume as air flows through the filter medium at the final resistance value;

generate a filter loading table that compares;

one or more resistance values of the filter medium having values bounded by the initial resistance value and the final resistance value; and

one or more operating speeds of the fan, the one or more operating speeds representing, for each resistance value, an operating speed of the fan at that resistance value for achieving the target output volume, the one or more operating speeds having values bounded by the initial operating speed and the final operating speed, wherein the filter loading table is usable to determine operating speeds of the fan given resistance values of the filter medium and the target output volume;

instruct the fan to operate at or about a relative maximum operating speed set at the initial operating speed for a fixed period of time;

receive, at the end of the fixed period of time, from the pressure sensing system, an observed differential pressure corresponding to an intermediate resistance value of the filter medium in a transitional condition;

determine, based on the observed differential pressure and the filter loading table, an updated operating speed for the fan to achieve the target output volume; and

instruct the fan to operate in accordance with a new relative maximum operating speed set at the updated operating speed.

2. The system of claim 1, wherein the management device is further configured to:

after instructing the air handler to operate at the new relative maximum operating speed, instruct the fan to operate at or about the new relative maximum operating speed for a second fixed period of time;

at the end of the second fixed period of time, receive, from the pressure sensing system, a second observed differential pressure corresponding to a second intermediate resistance value of the filter medium in a second transitional condition;

determine, based on the second observed differential pressure and the filter loading table, a second updated operating speed for the fan to achieve the target output volume; and

instruct the fan to operate at a second new relative maximum operating speed set at the second updated operating speed.

3. The system of claim 1, wherein the filter loading table is based on a linear or a logarithmic interpolation between:

the initial resistance value and the initial operating speed; and

the final resistance value and the final operating speed.

4. The system of claim 1, wherein the final operating speed is determined based at least in part on a fan curve corresponding to the fan of the air handler.

5. The system of claim 1, wherein determining the updated operating speed comprises adjusting a setting of a speed controller such that the updated operating speed is equal to the new relative maximum operating speed for the fan, the new relative maximum operating speed being less than or equal to a maximum rated speed of the fan.

6. The system of claim 1, wherein instructing the fan to operate at or about the maximum relative operating speed for the fixed period of time, receiving the observed differential pressure corresponding to the intermediate resistance value of the filter medium in the transitional condition, determining the updated operating speed for the fan, and instructing the fan to operate at the updated operating speed comprises a rebalancing process, the rebalancing process repeated according to a periodic interval during a useable lifetime of the filter medium.

7. The system of claim 1, wherein the management device is further configured to:

generate an output when the intermediate resistance value approaches, meets, or exceeds the final resistance value, the output recommending that the filter medium be replaced; and

provide the output to a building management system.

8. A computer-implemented method, comprising:

instructing a fan of an air handler to operate at an initial operating speed, the initial operating speed selected such that the air handler achieves a target output volume with a filter having an initial resistance value;

instructing the fan to operate at or about a relative maximum operating speed based upon the initial operating speed for a fixed period of time;

after the fixed period of time, accessing, from a pressure sensing system, an observed differential pressure corresponding to an intermediate resistance value of the filter in a transitional condition;

determining, based on the observed differential pressure and a table of values, an updated operating speed for the fan such that the air handler achieves the target output volume, the table of values comprising;

one or more resistance values of the filter having values bounded by the initial resistance value and a final resistance value, the final resistance value representing an increased resistance in the filter attributable to particle accumulation in the filter, each resistance value of the one or more resistance values corresponding to a pressure drop attributable to the filter; and

one or more operating speeds of the fan, each associated with one or more of the resistance values and representing an operating speed of the fan at the resistance value to produce the target output volume, wherein the table of values is usable to determine operating speeds of the fan given resistance values of the filter and the target output volume; and

instructing the fan to operate at an adjusted maximum operating speed associated with the updated operating speed.

9. The computer-implemented method of claim 8, wherein the resistance values for the filter increase as the filter transitions from the initial resistance value to a dirty condition having a final resistance value.

10. The computer-implemented method of claim 8, wherein the table is based on a linear or a logarithmic interpolation between:

the initial resistance value and the initial operating speed; and

the final resistance value and a final operating speed.

11. The computer-implemented method of claim 8, wherein the observed differential pressure comprises an average differential pressure determined from two or more pressure readings collected by the pressure sensing system during the fixed period of time.

12. The computer-implemented method of claim 8, wherein determining the updated operating speed comprises adjusting a setting of a speed controller such that the updated operating speed is equal to an updated relative maximum operating speed for the fan, the updated relative maximum operating speed being less than or equal to a maximum rated speed of the fan.

13. The computer-implemented method of claim 8, further comprising determining, based at least in part on the final resistance value of the filter and the target output volume, a final operating speed for the fan such that the air handler achieves the target output volume as air flows through the filter.

14. The computer-implemented method of claim 8, further comprising:

determining, based at least in part on the intermediate resistance value, an estimated remaining life of the filter in the transitional condition; and

providing the estimated remaining life of the filter to a building management system.

15. The computer-implemented method of claim 8, wherein the pressure sensing system comprises a manometer, a first static tip, and a second static tip.

16. The computer-implemented method of claim 15, wherein the first static tip is disposed near a first side of the filter and the second static tip is disposed near a second side of the filter, the first side opposite the second side, and wherein the differential pressure is measured across the filter.

17. The computer-implemented method of claim 15, wherein the first static tip is disposed near an inlet of the air handler and the second static tip is disposed near an outlet of the air handler, and wherein the differential pressure is measured across the air handler from the first static tip to the second static tip.

18. One or more computer-readable storage devices for storing computer executable instructions that, when executed by one or more computer systems, configure the one or more computer systems to perform operations comprising:

instructing a fan of an air handler to operate at or about a first relative maximum operating speed for a first fixed period of time, the relative maximum operating speed set to achieve a target output volume through a filter medium having an initial resistance value in a clean condition, the initial resistance value corresponding to an initial pressure drop attributable to the filter medium;

accessing, after the first fixed period of time, from a pressure sensing system, a first observed differential pressure corresponding to a first intermediate resistance value of air flow by the fan through the filter medium in a first transitional condition;

determining, based at least in part on the first observed differential pressure and a set of filter loading values, a first updated operating speed for the fan such that the air handler achieves the target output volume, the set of filter loading values representing resistance values for fan flow through the filter medium that increase as the filter medium transitions from the clean condition having the initial resistance value to a dirty condition representing particulate within the filter medium, wherein the set of filter loading values is usable to determine operating speeds of the fan given resistance values of the filter medium and the target output volume; and

instructing the fan to operate in accordance with an adjusted relative maximum operating speed based upon the first updated operating speed.

19. The one or more computer-readable storage devices of claim 18, wherein the computer-executable instructions configure the one or more computer systems to further perform operations comprising:

in accordance with a balancing interval, accessing, from the pressure sensing system, a second observed differential pressure corresponding to a second intermediate resistance value of the filter medium in a second transitional condition, the second observed differential pressure measured at least across the filter medium during a second fixed period of time, the second intermediate resistance value greater than the first intermediate resistance value;

determining, based at least in part on the second observed differential pressure and a subset of the set of filter loading values, a second updated operating speed for the fan such that the air handler achieves the target output volume; and

instructing the fan to operate in accordance with the second updated operating speed.

20. The one or more computer-readable storage devices of claim 18, wherein the computer-executable instructions configure the one or more computer systems to further perform operations comprising:

determining, based at least in part on the first intermediate resistance value, an estimated remaining life of the filter medium in the first transitional condition; and

providing the estimated remaining life of the filter medium to a building management system.