HVAC system remote monitoring and diagnosis

• US 9,741,023 B2
• Filed: 02/28/2013
• Issued: 08/22/2017
• Est. Priority Date: 02/28/2012
• Status: Active Grant

• Current Assignee: Emersub Cxiii Incorporated (Emerson Electric Company)
• Original Assignee: Emerson Electric Company
• Inventors: Arensmeier, Jeffrey N., Cox, Jr., Steven A., Layton, Paul
• Primary Examiner(s): Ruhl, Dennis
• Application Number:
  US13/780,617
• Publication Number:
  US 20140074730A1
• Time in Patent Office: 1,636 Days
• Field of Search: 705305
• 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 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/47 Responding to energy costs
• CPC Class Codes: F24F 11/49 ensuring correct operation, e.g. by trial operation or configuration checks
• CPC Class Codes: F24F 11/52 Indication arrangements, e.g. displays
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A method of operating a heating, ventilation, or air conditioning (HVAC) monitoring service is described. The method includes: providing a local device for installation in an HVAC system of a residential or commercial building; periodically receiving data from the local device across a wide area network, wherein the received data includes electrical sensor data including at least one of current or power; and storing the received data. The method further includes: analyzing the stored data to selectively identify problems and selectively predict faults of the HVAC system; receiving a subscription fee corresponding to the building, the subscription fee applying to a calendar period; and during the calendar period, providing information on the identified problems and the predicted faults to a customer corresponding to the building.

Claims

1. A method of operating a heating, ventilation, or air conditioning (HVAC) monitoring service by a remote monitoring system including a processor and a memory, the method comprising:

providing a local device for installation in an HVAC system of a residential or commercial building, the HVAC system having a plurality of components, the local device being configured to collect data from a single current sensor, wherein the collected data from the single current sensor is representative of an aggregate current draw of the plurality of components of the HVAC system as measured by the single current sensor, and wherein the local device is configured to transform the collected data into frequency domain current data;

at the remote monitoring system, periodically receiving frames of information from the local device across a wide area network, wherein each frame of the frames corresponds to a window of time and includes (i) frequency domain current data calculated by the local device from a plurality of time domain current samples measured by the local device during the window of time and (ii) a single time domain current value based on the plurality of time domain current samples;

storing the received frequency domain current data in the memory of the remote monitoring system;

using the processor of the remote monitoring system, executing a frequency domain analysis to (i) analyze the stored frequency domain current data to determine an individual contribution of at least one of the plurality of components of the HVAC system without individual current data from a plurality of individual current sensors respectively configured for monitoring each of the plurality of components and (ii) selectively identify problems occurring in the at least one of the plurality of components of the HVAC system based on the determined individual contribution;

receiving a subscription fee corresponding to the building, the subscription fee applying to a calendar period; and

in response to at least one of the problems being identified, selectively transmitting an alert message to a customer corresponding to the building, wherein the transmitting is restricted to the calendar period.

2. The method of claim 1 further comprising selling the local device, wherein a price of the local device includes the subscription fee, and wherein the calendar period begins when the local device is activated.

3. The method of claim 2 wherein the price of the local device includes a lifetime subscription and the calendar period has no end date.

4. The method of claim 1 wherein the building is a residence and the customer is a homeowner of the residence.

5. The method of claim 1 wherein the local device is installed by a first HVAC contractor.

6. The method of claim 5 wherein the subscription fee is received from the first HVAC contractor.

7. The method of claim 6 wherein the customer pays the first HVAC contractor a service fee for a maintenance plan, and wherein the subscription fee is paid by the first HVAC contractor from the service fee.

8. The method of claim 5 wherein the alert message on the identified problems is also provided to the first HVAC contractor.

9. The method of claim 8 wherein additional information on the identified problems is provided to the first HVAC contractor.

10. The method of claim 5 further comprising providing part information to the first HVAC contractor, wherein the part information includes a list of one or more parts expected to be used in remedying the identified problems.

11. The method of claim 5 further comprising providing skill information to the first HVAC contractor for use in selecting a technician, wherein the skill information includes a list of skills expected to be needed in remedying the identified problems.

12. The method of claim 1 further comprising providing a second local device for installation at the building.

13. The method of claim 12 wherein the local device is located proximate to an air handler unit of the HVAC system and wherein the second local device is located proximate to a condensing unit of the HVAC system.

14. The method of claim 13 wherein the collected data includes (i) electrical sensor data of the air handler unit measured by the local device and (ii) electrical sensor data of the condensing unit measured by the second local device.

15. The method of claim 1 wherein the alert message includes at least one of a voicemail message, a text message, or an email message.

16. The method of claim 1 wherein the alert message includes contact information for an HVAC contractor.

17. The method of claim 1 wherein the alert message includes a telephone call to the customer.

18. The method of claim 1 wherein selectively identifying problems includes selectively identifying a reduced efficiency of the HVAC system in response to the stored data.

19. The method of claim 18 further comprising waiting to send information regarding the reduced efficiency to the customer until the reduced efficiency falls below a threshold.

20. The method of claim 19 further comprising determining the threshold based on a make and model number of the HVAC system.

21. The method of claim 19 further comprising determining the threshold based on an initial efficiency determination performed on the HVAC system.

22. The method of claim 1 wherein the wide area network includes the Internet.

23. The method of claim 1 further comprising aperiodically receiving data over the wide area network in response to events in the HVAC system.

24. The method of claim 23 wherein the events include at least one of (i) a request for heating from a thermostat of the HVAC system and (ii) a request for cooling from the thermostat.

25. The method of claim 1 wherein the collected data comprises electrical sensor data that includes current and voltage.

26. The method of claim 25 wherein the electrical sensor data includes power and power factor.

27. The method of claim 1 wherein the collected data includes time domain current data having a first resolution, and wherein the frequency domain current data was generated by the local device based on time domain current data having a second resolution higher than the first resolution.

28. The method of claim 1 wherein the collected data includes air temperature sensor data and refrigerant temperature sensor data.

29. The method of claim 1 wherein the collected data includes air pressure sensor data.

30. The method of claim 1 wherein the collected data includes refrigerant pressure sensor data.

31. The method of claim 1 further comprising providing aggregated and anonymized data to original equipment manufacturers of HVAC equipment.

32. The method of claim 31 wherein the aggregated and anonymized data includes system efficiency data.

33. The method of claim 31 wherein the aggregated and anonymized data includes repair data.

34. The method of claim 1 further comprising at the remote monitoring system, comparing received data from before a repair was performed with received data from after the repair was performed.

35. The method of claim 34 further comprising informing the customer of a result of the comparison.

36. The method of claim 35 further comprising providing a graph of operating parameters of the HVAC system including a time period before the repair was performed and a time period after the repair was performed.

37. The method of claim 1 further comprising notifying a technician of the identified problems, wherein the technician analyzes the identified problems before information is provided to the customer.

38. The method of claim 37 further comprising providing contact information for the technician to an HVAC contractor to allow the HVAC contractor to discuss the identified problems with the technician.

39. The method of claim 1 further comprising selectively providing, to the customer, a recommendation to replace a consumable of the HVAC system.

40. The method of claim 39 wherein the consumable is an air filter.

41. The method of claim 39 further comprising shipping the consumable to the building.

42. The method of claim 39 further comprising directing an HVAC contractor to deliver the consumable to the building.

43. The method of claim 1 further comprising selectively providing, to at least one of an HVAC contractor or the customer, a recommendation to perform preventative maintenance.

44. The method of claim 43 wherein the preventative maintenance includes one or more of cleaning evaporator coils of the HVAC system and cleaning condenser coils of the HVAC system.

45. The method of claim 1 further comprising, in response to identified problems:

estimating a repair cost for the at least one of the plurality of components;

estimating a replacement cost for at least a subsystem of the HVAC system; and

providing a graphical interface to the customer including the repair cost and the replacement cost.

46. The method of claim 45 wherein the graphical interface includes a repair history of the HVAC system.

47. The method of claim 45 wherein the graphical interface includes an estimation of utility costs (i) after repairing the HVAC system and (ii) after replacing the HVAC system.

48. The method of claim 1 further comprising:

providing a graphical interface to the customer; and

in the graphical interface, displaying a timeline of operating parameters of the HVAC system,

wherein the operating parameters are obtained from the stored data.

49. The method of claim 48 further comprising, in the graphical interface, displaying the timeline with graphical data.

50. The method of claim 48 further comprising, in the graphical interface, displaying the timeline with textual data.

51. The method of claim 48 further comprising, in the graphical interface, displaying raw numbers from the stored data.

52. The method of claim 48 wherein the local device was installed in the HVAC system at a first point in time, and wherein the stored frequency domain current data covers from the first point in time to a present point in time.

53. The method of claim 52 further comprising allowing the customer to zoom in on a selected time period of the stored data.

54. The method of claim 1 wherein for a first frame of the frames, the single time domain current value is calculated as a root mean square of the plurality of time domain current samples for the window of time corresponding to the first frame.

55. The method of claim 1 wherein the window of time for each frame of the frames corresponds to measurement of 256 time domain current samples.