This Application is a National Stage of International Application No. PCT/EP2017/063166 filed May 31, 2017, claiming priority based on Switzerland Patent Application No. 00714/16 filed Jun. 3, 2016.

FIELD OF THE INVENTION

The present invention relates to a method and a computer system for monitoring an HVAC system. Specifically, the present invention relates to a method and a computer system for monitoring an HVAC system which comprises a plurality of HVAC devices and a plurality of HVAC controllers, each of the HVAC controllers comprising a communication module.

BACKGROUND OF THE INVENTION

In the field of Heating, Ventilation, Air Conditioning, and Cooling (HVAC), HVAC systems comprise a fluid transportation system and a plurality of HVAC devices, including motorized HVAC devices, such as actuators, valves, dampers, pumps, and fans, and other devices connected to the HVAC system, such as flow senses, pressure sensors, temperature sensors, rotation sensors, position sensors, humidity sensors, etc. In addition to an electric motor, motorized HVAC devices or HVAC actuators, respectively, are typically provided with a controller having a processing unit and a data store for storing configuration data for operating the HVAC device, and for recording operation-related data by the HVAC device. In the field of HVAC, the electric motor is coupled, through gears and/or other mechanical coupling, to a valve or damper for controlling the flow of a fluid such as water or air. The configuration data includes configuration parameters such as motor speed, closing time, opening time, etc. The operation-related data includes values such as number of cycles, number of movements, maximum travel angle, minimum travel angle, etc. In HVAC applications, the controller is connected to sensors, such as flow sensors, pressure sensors, temperature sensors, rotation sensors, position sensors, etc., and the configuration data further includes configuration parameters such as a target value of flow rate, a set value of altitude for adjusting the measurement of a flow sensor, etc. Moreover, a section of the data store further has stored therein program code for controlling the processing unit. In HVAC applications, the program code includes various control algorithms for controlling the motor to open and close an orifice of the value or damper to regulate the flow of fluid e.g. with regards to differential pressure, room temperature, flow of energy, etc. Although the storing of configuration data, program code, and/or operation-related data would make possible flexible management and operation of HVAC systems and their actuators and other HVAC devices, the actual management and operation of HVAC systems and their actuators and other HVAC devices is typically not as advanced as it could be. The reasons for this include the facts that the HVAC actuators and other HVAC devices are typically installed in locations which are not often accessed and/or are not easily accessible, they are not always connected to a communication network, and most importantly, even when an operator has access to the configuration and operation-related data of an HVAC actuator or another HVAC device, it is very difficult, if not impossible, to assess from this data whether the HVAC actuator or other HVAC device is operating properly and within specified conditions, whether there is problem with regards to the electrical and mechanical condition and operation of the HVAC actuator or other HVAC device, or their actual application and performance, or whether the actuator or some of its attached components and other HVAC devices need to be reconfigured or even replaced, because the answers to these questions depend on further factors, such as current and past environmental conditions (e.g. humidity, temperature), past performance and load of the specific HVAC actuator or other HVAC device, and past performance history with the particular type of HVAC actuator or other HVAC device. Thus, it would be desirable to improve the actual monitoring of HVAC systems, whereby the term “monitoring of an HVAC system” is not limited to merely observing behavior and performance of an HVAC system and its actuators and other HVAC devices, but also includes enabling and drawing qualified conclusions with respect to performance and/or conditions of a particular actuator or other HVAC device.

SUMMARY OF THE INVENTION

It is an object of this invention to provide a method and a computer system for monitoring an HVAC system, which method and computer system do not have at least some of the disadvantages of the prior art. In particular, it is an object of the present invention to provide a method and a computer system for monitoring an HVAC system and its HVAC actuators and other HVAC devices, which method and computer system do not have at least some of the disadvantages of the prior art.

According to the present invention, these objects are achieved through the features of the independent claims. In addition, further advantageous embodiments follow from the dependent claims and the description.

An HVAC system comprises a plurality of HVAC devices and a plurality of HVAC controllers. Each of the HVAC controllers comprises a communication module. Examples of HVAC devices include motorized HVAC devices, such as actuators, valves, dampers, pumps, and fans, and other, non-motorized devices associated with the HVAC system, such as sensors.

According to the present invention, the above-mentioned objects are particularly achieved in that for monitoring the HVAC system, HVAC data reporting messages are received and stored in a cloud-based computer system. Each HVAC data reporting message includes one or more operational data values included by one of the HVAC controllers. The cloud-based computer system generates remote diagnoses for a particular HVAC device of the HVAC system, using a plurality of HVAC data reporting messages received from a plurality of the HVAC controllers from one or more HVAC systems. Each remote diagnosis is generated by using more than one operational data value. The cloud-based computer system transmits a diagnosis message to a diagnosis processing system for the particular HVAC device. The diagnosis message includes a remote diagnosis for the particular HVAC device.

In an embodiment, the cloud-based computer system generates the remote diagnosis for the particular HVAC device by using operational data values included in HVAC data reporting messages received from HVAC controllers of more than one HVAC systems.

In a further embodiment, the HVAC controllers include in the HVAC data reporting messages at least two different types of operational data values. The cloud-based computer system generates the remote diagnosis for the particular HVAC device by using at least the two different types of operational data values from the HVAC controllers.

In an embodiment, the HVAC controllers include in the HVAC data reporting messages sensor measurement values from at least two different sensors connected to the respective HVAC controller. The cloud-based computer system generates the remote diagnosis for the particular HVAC device by using sensor measurement values from at least two different sensors connected to the HVAC controller.

In a further embodiment, the cloud-based computer system determines location information for the HVAC devices. The cloud-based computer system generates the remote diagnosis for the particular HVAC device by further using location information of the HVAC devices.

In an embodiment, the cloud-based computer system generates one or more HVAC device group reference values, using a plurality of data reporting messages received from a plurality of HVAC controllers of a plurality of HVAC systems. The cloud-based computer system generates the remote diagnosis for the particular HVAC device by using at least one of the HVAC device group reference values and at least one HVAC data reporting message related to the particular HVAC device.

In a further embodiment, the cloud-based computer system determines HVAC device benchmark data indicative of functional performance levels of the HVAC devices, using a plurality of the HVAC data reporting messages received from a plurality of HVAC controllers of a plurality of HVAC systems. The cloud-based computer system determines an individual performance indicator for the particular HVAC device, using the HVAC device benchmark data and at least one HVAC data reporting message related to the particular HVAC device. The cloud-based computer system transmits a diagnosis message to a diagnosis processing system for the particular HVAC device, depending on the individual performance indicator of the particular HVAC device.

In an embodiment, the cloud-based computer system determines for the HVAC devices performance thresholds which define expected normal operations of the HVAC devices, using a plurality of HVAC data reporting messages received from a plurality of HVAC controllers of a plurality of HVAC systems. The cloud-based computer system identifies a particular HVAC device which operates outside the expected normal operations defined by the performance thresholds, using one or more HVAC data reporting messages related to the particular HVAC device. The cloud-based computer system generates and transmits an abnormal operations alert message to the diagnosis processing system responsible for the particular HVAC device.

In a further embodiment, the cloud-based computer system determines operational end-of-life expectancies for HVAC device components of the HVAC devices or for HVAC device components connected to the HVAC devices, using a plurality of HVAC data reporting messages received from a plurality of HVAC controllers of a plurality of HVAC systems. The cloud-based computer system identifies an HVAC device component which has reached its operational end-of-life expectancy, using one or more HVAC data reporting messages related to the HVAC device comprising or being connected to the respective HVAC device component. The cloud-based computer system generates and transmits an end-of-life alert message to a diagnosis processing system responsible for the respective HVAC device component or HVAC device.

In an embodiment, the cloud-based computer system detects oscillation of control or feedback signals, using a plurality of HVAC data reporting messages received from HVAC controllers of a particular HVAC system. Upon detection of oscillation, the cloud-based computer system determines control parameters for attenuating the oscillation and transmits the control parameters to one or more HVAC controllers of the particular HVAC system.

In a further embodiment, the cloud-based computer system generates control values for the particular HVAC device, using a plurality of data reporting messages received from a plurality of HVAC controllers. Each control value is generated by using more than one operational data value. The cloud-based computer system transmits a control message to the particular HVAC device, the control message including a control value for the particular HVAC device.

In an embodiment, at least some of the operational data values relate to operational parameters of an electric motor of an HVAC actuator, the operational parameters of the electric motor relating to: motor current of the electric motor, voltage levels of a power supply of the electric motor, temperature of the electric motor, and/or movement of the electric motor. The operational parameters of the electric motor relating to movement include: number of rotations, number of changes of direction, powered-on operating time, active operating time, number of starts, number of stops, and/or start/stop ratio.

In a further embodiment, at least some of the operational data values relate to positions of actuated parts actuated by HVAC actuators.

In an embodiment, at least some of the operational data values relate to sensor measurements values regarding a fluid moving through a valve controlled by an HVAC actuator, including: flow rate, temperature values, and/or differential pressure values.

In addition to a method for monitoring an HVAC system: the present invention also relates to a computer system for monitoring an HVAC system. The computer system is a cloud-based computer system and comprises one or more processors configured to: receive and store in the cloud-based computer system HVAC data reporting messages from the plurality of HVAC controllers, each HVAC data reporting message including one or more operational data values included by the respective controller; generate remote diagnoses for a particular HVAC device of the HVAC system, using a plurality of HVAC data reporting messages received from a plurality of the HVAC controllers from one or more HVAC systems, wherein each remote diagnosis is generated by using more than one operational data value; and transmit a diagnosis message to a diagnosis processing system for the particular HVAC device, the diagnosis message including a remote diagnosis for the particular HVAC device.

In an embodiment, the method is directed to monitoring a plurality of HVAC actuators, each of the HVAC actuators comprising an electric motor, a controller, and a communication module, actuator data reporting messages are received and stored in a cloud-based computer system. Each actuator data reporting message includes one or more operational data values from the controllers of the HVAC actuators. The cloud-based computer system generates remote diagnoses for a particular one of the HVAC actuators, using a plurality of data reporting messages received from a plurality of the HVAC actuators. Each remote diagnosis is generated by using more than one operational data value. The cloud-based computer system transmits a diagnosis message to a diagnosis processing system for the particular one of the HVAC actuators. The diagnosis message includes a remote diagnosis for the particular one of the HVAC actuators. In an embodiment, the cloud-based computer system generates the remote diagnosis for the particular one of the HVAC actuators by using operational data values included in data reporting messages received from more than one of the HVAC actuators.

In addition to a method and a cloud-based computer system for monitoring an HVAC system and/or a plurality of HVAC actuators, the present invention also relates to an HVAC actuator, comprising an electric motor, a controller, and a communication module, wherein the controller is configured to: determine and store in a data store of the respective controller one or more operational data values; generate actuator data reporting messages, each actuator data reporting message including at least one of the operational data values; transmit the actuator data reporting messages from the HVAC actuator addressed to a cloud-based computer system using the communication module of the HVAC actuator; and receive from the cloud-based computer system a diagnosis message, the diagnosis message including a remote diagnosis generated by the cloud-based computer system for the HVAC actuator from more than one operational data value, using a plurality of data reporting messages from a plurality of HVAC actuators.

In addition, the present invention also relates to a method and a cloud-based computer system for monitoring a plurality of HVAC actuators, each of the HVAC actuators comprising an electric motor, a controller, and a communication module. Actuator data reporting messages are received and stored in a cloud-based computer system. The actuator data reporting message include measurement values of a motor current (or motor torque) of the electric motor of an HVAC actuator, and motor movement information. The cloud-based computer system determines system hysteresis for a particular HVAC actuator from a course of the motor current (or motor torque) and the motor movement. The system hysteresis is indicated by a reduced motor current (or motor torque) during directional changes of the motor, until the motor current (or motor torque) increases, upon engaged actuation of an actuated part actuated by the motor. The cloud-based computer system generates remote diagnoses of increased system hysteresis for a particular actuator based on a comparison of the system hysteresis determined for the particular actuator to the system hysteresis determined and recorded in the past for the particular actuator.

