DIGITAL CONTROLLER FOR AIR CONDITIONER USED IN ENCLOSURE COOLING

An example implementation includes a method of monitoring and controlling an air conditioning unit. An example method includes obtaining, from a sensor disposed in an air conditioning unit, data indicative of one or more of current and vibration associated with a physical component of the air conditioner; analyzing, using one or more of a processor and a circuit, the data; determining, based on the analyzing, that the data indicates that the physical component may fail; and providing, responsive to the determining, an indication of failure.

BACKGROUND

Industry and manufacturing have emerged with the widespread use of enclosures for a variety of items, for example electronics or other items that require protection from the elements as well as cooling. To protect these items from harsh environments, they are typically placed in sealed enclosures or workstations that permit efficient operation without the threat of being exposed to exterior contaminates including dust, residue, rain and liquids that have the potential to cause serious damage. Since the items (such as electronics used in the telecommunications industry or like equipment) often generate heat within the enclosure, various cooling equipment such as air conditioners, heat exchangers, in-line compressed air coolers and filtered fan systems are used to maintain required operating temperatures within the enclosure. In some cases, such cooling equipment may be provided as an addition to the enclosure, e.g., a cooling system may be provided separately and attached to an enclosure.

BRIEF SUMMARY

The subject matter disclosed herein relates to enclosure cooling systems and related techniques. Some of the subject matter disclosed herein relates to a digital controller for a cooling system that is mounted to an enclosure and used for cooling items within the enclosure, such as heat generating components or other contents within the enclosure.

Since items in an enclosure (such as electronics used in communication, computation, displaying data, dispensing mechanisms or like equipment and/or items in the enclosure, e.g., to be dispensed) often generate heat within an enclosure or otherwise need to be cooled, such as items in a vending or dispensing machine, various cooling equipment such as air conditioners, heat exchangers, in-line compressed air coolers and filtered fan systems may be used to maintain required operating temperatures within the enclosure.

An embodiment provides an air conditioner that utilizes a housing fitted to an enclosure. An embodiment provides cooling to the enclosure and its contents while allowing for wired or wireless control of the air conditioning unit via a digital controller. An embodiment may be mounted on the outside of an enclosure to be cooled, e.g., on the top of or inside of the enclosure. One or more cutouts on the enclosure interface(s) with one or more intake(s) and return(s) on the air conditioning unit, facilitating circulation or provision of cooling to the enclosure interior.

In summary, an embodiment provides a method, comprising: obtaining, from a sensor disposed in an air conditioning unit, data indicative of one or more of current and vibration associated with a physical component of the air conditioner; analyzing, using one or more of a processor and a circuit, the data; determining, based on the analyzing, that the data indicates that the physical component may fail; and providing, responsive to the determining, an indication of failure.

The method may include the indication being provided to one or more remote devices over an internet connection.

The method may comprise receiving configuration data for configuring one or more set points for the air conditioning unit. The configuration data may be received from a mobile device. The configuration data may be derived from one or more templates associated with one or more predetermined operating scenarios. The one or more predetermined operating scenarios may comprise a lead-lag operating scenario. The configuration data may be received via manual input. The manual input may configure one or more dip switches and or provide configuration input to a controller interface such as a touch screen interface. In one example, the configuration data is received responsive to brining a predetermined mobile device into proximity of the air conditioning unit.

In an embodiment, the analyzing of the sensor data comprises one or more of comparing the data to one or more thresholds and detecting a pattern or trend in the data.

An embodiment includes a device for implementing the various techniques described herein. In one example, the device, comprises: a component including one or more of a fan and a compressor; a sensor configured to monitor the component; and a controller operatively coupled to the component; the controller configured to: obtain, from the sensor, data indicative of one or more of current and vibration associated with the component; analyze the data; determine, based on analyzing the data, that the data indicates that the component may fail; and thereafter provide an indication of failure.

The device may provide the indication to one or more remote devices over an internet connection. In one example, the controller is configured to receive configuration data for configuring one or more set points for the device. The configuration data may be received from a mobile device. The configuration data received from the mobile device may be derived from one or more templates associated with one or more predetermined operating scenarios. The one or more predetermined operating scenarios may comprise a lead-lag operating scenario.

The device may be configured to receive the configuration data via manual input. The device may comprise one or more dip switches, wherein the manual input configures the one or more dip switches. In one example, the controller of the device is configured to detect the configuration data responsive to brining a predetermined mobile device into proximity of the device.

A further embodiment provides a system, comprising: a device as described herein; and a mobile application comprising one or more templates for receiving configuration data associated with one or more predetermined operating scenarios.

A yet further embodiment comprises a product comprising computer executable code configured to implement one or more of the functions or acts specified herein.

DETAILED DESCRIPTION

Reference throughout this specification to “embodiment(s)” (or the like) means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “according to embodiments” or “in an embodiment” (or the like) in various places throughout this specification are not necessarily all referring to the same embodiment.

Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of example embodiments. One skilled in the relevant art will recognize, however, that aspects can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obfuscation.

The description now turns to the figure(s), which illustrate certain example embodiments. The dimensions and other numerical information provided herein, including in the figures, are provided only by way of example and are not limiting unless specifically included in a claim. In the figure(s), certain example dimensions are provided in millimeters.

Referring toFIG.1, a system100is illustrated in which a view of an example an air conditioner unit102is provided. The view ofFIG.1is provided to illustrate that an enclosure101to be cooled by an air conditioner102, e.g., mounted to the side, as shown in the non-limiting example ofFIG.1, may include a controller103, e.g., mounted to the inside of the air conditioner102.

Turning toFIG.1B, illustrated is the enclosure101, air conditioner102, controller103, and communication element104(e.g., Ethernet port, which may be a different or additional port, such as Modbus) for wired communication with a remote device, such as a computer. In addition, as described herein, controller103may include various wireless radios or communication elements, e.g., for near field, personal area network, short range wireless, or wireless internet communication with a remote or external device105(noting that device105may be a mobile device brought into proximity of controller103to automate certain communications, e.g., via RFID, near field communication, etc.).

The example air conditioning unit102includes cooling components such as a compressor and evaporator needed to condition enclosure101air, inlets and returns for taking in enclosure101air and returning conditioned air to the enclosure101.

As shown inFIG.1, an embodiment includes a digital controller103to communicate with the fan(s) internal to the unit, the compressor, and other internal components. The digital controller103is used in conjunction with network connectivity, e.g., ethernet, for remote access and alerts, e.g., delivered via text message or email. The controller103may be mounted to the air conditioner102, e.g., inside the air conditioner102and out of sight if an external facing controller is not desirable. An internal controller permits the exterior surface of the unit to be free from controller footprint, e.g., allowing a cleaner or clearer exterior design.

In an embodiment, wireless communication is facilitated between the controller103and one or more remote devices105. For example, when near the air conditioning unit102and/or controller103, an operator may connect to the controller103wirelessly using a short range or near field wireless communication connection, a BLUETOOTH wireless communication connection, etc. In an embodiment, a remote device105used to control the controller103and the air conditioning unit102may take the form of a tablet computer or a smart phone. In an embodiment, the remote device105may have a mobile application installed that permits communication with the controller103via one or more appropriate wireless connections, such as via a personal area network such as BLUETOOTH communication or via a wide area network such as the Internet.

In an embodiment, the controller103may be programmed to control the air conditioning unit102via wireless communication, e.g., via a mobile application and graphical user interfaces (GUIs), such as provided via an ANDROID operating system or IOS mobile application, wired communication, e.g., ethernet, or via manual input, e.g., using a series of dip switches103aprovided in association with the controller103, e.g., in communication with a printed circuit board (PCB) of the controller103. For example, in an embodiment, the dip switches103amay be reached manually by an operator through an access panel that surrounds the controller103to set up the desired temperature set point(s), e.g., if a smart device105is not available or preferred for setting or configuring the air conditioning unit102wirelessly. The dip switches103amay be associated or connected pins on a PCB of the controller103, where a set or series of dip switches103amay be used to program set point(s) manually. An embodiment therefore includes both dip switches103aand software configurable controller, e.g., configurable via mobile application or remote device, offering a redundant control feature that may be used alone or in combination with another control feature.

Using a mobile application, the air conditioner102can be accessed with a security code or data, e.g., a four-digit security code, and all parameters, including setpoint(s), can be adjusted via the GUI interfaces. If two or more air conditioning units102are applied to an implementation, e.g., on or in connection with a single enclosure101to be cooled, the set points or other parameters can be configured in combination, e.g., using the mobile application. For example, the setpoint of one air conditioning102unit may be set to begin operation (cooling) at a higher temperature if the other, e.g., primary, air conditioner cannot adequately cool the enclosure. The two controllers of the air conditioning units, configured by the user, communicate with one another in a programmed fashion to accomplish such a lead-lag setup. In an embodiment, one or more template GUIs may be provided for the user in the mobile application, e.g., to automate or semi-automate configuring such a lead-lag or other set up arrangement. For example, the units102may be associated with one another via proximity to the device running the mobile application105, and a user may select a template or preconfigured settings to associate the controller(s)103of the units102. In this fashion, a user may not need to enter any data other than confirmation of the predetermined configuration(s) of the template or to adjust a reduced dataset, e.g., enter or adjust set point(s) for the unit(s), indicate a leading or primary unit, indicating a unit as a redundant unit, etc. In an embodiment, after configuration, one or more indicators, such as a light emitting diode, a user interface element, etc., on the air conditioning units may be updated to correspond to the configuration chosen, e.g., indicate a leading unit, to allow the user to confirm the configuration with the equipment.

In an embodiment, current and/or vibration sensor(s)106may be used in the air conditioning unit102in association with a sensed component106a, such as compressor, a fan, etc., and report data to the controller103and/or a remote device, e.g., device105running the mobile application. In an embodiment, a current sensor106may be utilized to detect current of a component106a, e.g., a compressor, and compare the current to a predetermined threshold or range. Using such data, the controller103or other programmable process, e.g., implemented at a remote device105, may determine that a component106ais out of range, below or above a threshold value, etc. Such a determination may lead to an automated action, e.g., an indication, an alert, an alarm, an automatic configuration adjustment (e.g., change in set point(s)), etc. For example, a given component106amay be expected to draw a certain amount or range or current. If a current sensor106reports to the controller103that the current is below this value or another value, e.g., a lower threshold, the controller103or device in communication there-with may produce an alert or alarm that appears on a remote device105, e.g., the device that is running the mobile application.

In an embodiment, one or more vibration sensors106may also report sensed data to the controller(s)103, e.g., report vibration data from one or more components106a, such as the fans. In an embodiment, the vibration data may be used to detect a pattern, signature, or amount of vibration from a component such as a fan to indicate the component106ais nearing its end of life. In an embodiment, the vibration sensor data is compared to a known set of vibration data to produce an estimated remaining life, which can be sent as an indication, alert or alarm. In an embodiment, different estimates of remaining life may result in different automated actions, e.g., providing an indication for a first remaining life estimate, thereafter, providing an alert for a reduced remaining life estimate, and providing an alarm and escalation message, e.g., email, text, push notification, email, etc., when end of life estimate is imminent or the component106ahas failed. As with other alerts, notifications, and events, event data may be stored, for example in a memory associated with a controller, which may be included in a remote device. This event data may be utilized to determine or inform decisions related to other components, e.g., incorporated into an automated learning process as labeled training data for making classifications.

An embodiment may be provided with alternating current (AC) power, direct current (DC) power, or a combination thereof, for example where DC battery power is provided as a backup power supply. In some embodiments, separate control of AC and DC supplied to the unit102is provided via a controller or combination of controllers103, as described herein.

An embodiment provides an air conditioner102that runs on direct current, e.g., 48 vdc, that operates at variable speeds to provide closed-loop cooling. An embodiment may take the form of an inset mounted air conditioner102for enclosure101cooling.

Variable speed is achieved through a driver that is controlled by a controller103with milliamp outputs to the driver that in turn varies the speed of a component106asuch as a fan or a compressor. A digital controller or control pad103may be provided for manual adjustments or other inputs.

An embodiment employs high and low set points for variable speed control, e.g., according to a control program executed by the controller103an/or programmed via dip switches103a. In an embodiment, both the high and low set points are adjustable. Adjusting the low setpoint or the high set point will affect the speed of the compressor and fan(s), as well as how fast the air conditioner102ramps up to full speed.

In an embodiment, components106asuch as one or more of a compressor and fan(s) are powered on and the speed of the compressor or fan(s), or both, is adjusted based on the set point(s) and the current temperature within the enclosure101. For example, in an embodiment, ambient side fan(s) vary speed off the low set point and high setpoint to coincide with the compressor and reject heat at variable rates. Enclosure side fan(s) vary speed from the high set point and off setpoint, e.g., which have a seven-degree differential. As the temperature hits the high setpoint, evaporator fan(s) run at full speed and as the low setpoint is approached speed ramps down, allowing for less energy consumption, less noise (fewer decibels), and less heat absorption. When the temperature starts to rise above the off setpoint (e.g., seven degrees below the high setpoint), fan(s) begin to increase speed as the temperature gets closer to the high setpoint. Once the air temperature in the enclosure101reaches the high setpoint, the air conditioner102is running at full speed. Once temperature in the enclosure10lgoes above the low setpoint, the unit102will cycle on.

In an embodiment, the enclosure101to be cooled is a cellular cabinet or enclosure, for example a 5G telecommunications enclosure. A cellular communications enclosure or cabinet may be located for example in a cellular tower or at or near the top of a building.

In an embodiment, a simple network management protocol (SNMP) module may be included, e.g., within circuitry provided with an embodiment, for supporting an Ethernet connection via an Ethernet port104. An SNMP module supports a protocol that is common to other cellular cabinet components and network devices, permitting a common communication channel to be utilized for controlling the cooling equipment and other equipment in the cellular cabinet. Likewise, in an embodiment, Modbus 485 protocol, BACnet 485 protocol or another communication protocol may be supported via appropriate ports or interfaces.

In an embodiment, software drives a compressor and allows for automated protocols controlling the system components. In an embodiment, as the system ramps up, the fan speed is advanced as compared to that of the compressor, i.e., the fan is adjusted to increase its speed more than the compressor speed. In an embodiment, when ramping down, the fan speed operates in the opposite manner with respect to the compressor speed.

An embodiment may operate according to one or more automated protocols, which may be adjusted. By way of example, if a set point is at 80° F., a high set point is at 100° F., with the temperature climbing slowly (e.g., less than a degree per minute), a 20 degree temperature range between set points is the time/temperature spread for increasing components such as fan(s) to max speed. In this example, the fan uses the 20-degree spread to ramp the system up as the temperature fluctuates within this temperature range.

In an embodiment, sudden temperature change may be handled differently by controlling software as compared to gradual temperature changes. For example, with a sudden temperature rise, e.g., 5 degrees in under a minute, the fan(s) automatically ramp up more quickly, e.g., to maximum, than would otherwise be the case if the fan(s) were following a slow temperature change protocol. Even in the face of sudden temperature changes, a control protocol may be dynamically adjusted, e.g., based on thermostat feedback, which may be included in or in communication with a digital controller103. For example, if the fan(s) compensate for the sudden temperature change by slowing the rate of temperature increase, halting temperature increase, or reversing temperature increase, then the fan(s) can slow down to a normal glide path, e.g., along a predetermined or default rate of speed change using a different protocol. In one example, such control may be facilitated by a software program that works in combination with dip switches103a, e.g., software control provides granular control of component(s)106abetween set points established by dip switch settings.

In an embodiment, a mechanical overload compressor is combined with an electronic overload protection device. For example, temperature or current overload of the compressor may trip a mechanical overload protection device, e.g., as determined via data of sensor106, where an electronic overload protection device monitors for over current. An embodiment controls the current by watching for over-current or another anomaly. This provides a redundant system of protection.

Adjusting the setpoints to be further away from one another will increase the efficiency of the air conditioner102because this allows the compressor and the ambient side fan(s) to modulate to find a balance point in the cooling required and allows for the air conditioner to use less electricity (if a higher capacity is not needed).

In an embodiment, a remote control (e.g., via ethernet data communication) enables control of the speeds and any function of the unit102from anywhere in the world through several protocols.

In an embodiment, a touch screen controller, e.g., an LCD touch sensitive smart controller, is provided as a digital controller103in a control panel.

An embodiment includes a built in or programmable minimum off cycle to prevent short cycling.

An embodiment includes a high efficiency, variable speed compressor.

In an embodiment, a binary mount allows for the unit102to be mounted as an inset vertical mount, partially recessed into the application enclosure101, or vertical mount, where the mounting surface of the unit102is flush to the surface of the application enclosure101. In an embodiment, the binary mount utilizes removable and adjustable flanges for the inset vertical mount and removable threaded studs for the vertical mount. This increases the versatility of the unit and makes it easy for customers to opt for the inset vertical mount and vertical mount configurations.

InFIG.1Ban example method is illustrated. As indicated, an embodiment may be used to monitor one or more units, e.g., unit102ofFIG.1. In the example illustrated inFIG.1B, the monitoring includes obtaining data, such as obtaining sensor data at110, e.g., from sensor106ofFIG.1A. At120the data is analyzed according to a rule, e.g., as indicated in this example analyzed to determine if the data is indicative of failure, as illustrated at130. If not, the process may loop or continue, as shown.

If the data is indicative of failure, e.g., trending towards a failure condition, out of range, etc., as determined at130, an indication may be generated at140. For example, an indication may be provided via wired or wireless communication to a remote device, e.g., remote device105, displayed on a display panel of controller103, or a combination of the foregoing. Thereafter, data may be received at150to control the unit102, for example changing a configuration such as a set point, current amount, operating speed of a component, change of state, e.g., standby for permitting component replacement, etc. As may be appreciated, the data may be communicated in a wired or wireless fashion from a remote device to the controller. Additionally or alternatively, manual input to the controller, dips switches, or a combination thereof may be provided to change a configuration of the unit102or to otherwise adjust control, e.g., update operating parameters as indicated at160.

Referring toFIG.2, an example device that may be used in implementing one or more embodiments includes a device in the form of a computing device (computer)200, for example included in an embodiment, component thereof such as a controller103, and/or another system (e.g., a phone, tablet, laptop or desktop computer).

The computer200may execute program instructions or code configured to store and process data and perform other functionality of the embodiments, e.g., operate an air conditioning unit or sub components thereof to cool an enclosure using set point(s) temperature(s), generate alarms related to temperature(s), intrusions, etc. Components of computer200may include, but are not limited to, a processing unit210, which may take a variety of forms such as a central processing unit (CPU), a graphics processing unit (GPU), a programmable circuit or other programmable hardware, a combination of the foregoing, etc., a system memory controller240and memory250, and a system bus222that couples various system components including the system memory250to the processing unit210. It is noted that in certain implementations, computer200may take a reduced or simplified form, such as a micro-control unit implemented in a controller103of an air conditioner102, where certain of the components of computer200are omitted or combined.

The computer200may include or have access to a variety of non-transitory computer readable media. The system memory250may include non-transitory computer readable storage media in the form of volatile and/or nonvolatile memory devices such as read only memory (ROM) and/or random-access memory (RAM). By way of example, and not limitation, system memory250may also include an operating system, application programs, other program modules, and program data. For example, system memory250may include application programs such as variable speed control software, failure detection programs or modules, and/or air conditioner operational software. Data may be transmitted by wired or wireless communication, e.g., to or from first device to another device, e.g., communication between a remote device or system such as computer200and air conditioning system260, which itself may include a device like the computer200in a reduced form, such as in the form of a controller203.

A user can interface with (for example, enter commands and information) the computer200through input devices such as a touch screen, keypad, etc. In certain forms, a user may interface with special purpose hardware, such as aforementioned dip switches103a. A monitor or other type of display screen or device may also be connected to the system bus222via an interface, such as an interface230. The computer200may operate in a networked or distributed environment using logical connections to one or more other remote computers or databases. The logical connections may include a network, such local area network (LAN) or a wide area network (WAN) but may also include other networks/buses.

It should be noted that various functions described herein may be implemented using processor executable instructions stored on a non-transitory storage medium or device. A non-transitory storage device may be, for example, an electronic, electromagnetic, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples of a non-transitory storage medium include the following: a portable computer diskette, a hard disk, a random-access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), a solid-state drive, or any suitable combination of the foregoing. In the context of this document “non-transitory” media includes all media except non-statutory signal media.

Example embodiments are described herein with reference to the figures, which illustrate various example embodiments. It will be understood that the actions and functionality may be implemented at least in part by program instructions. These program instructions may be provided to a processor of a device to produce a special purpose machine, such that the instructions, which execute via a processor of the device implement the functions/acts specified.

It is worth noting that while specific elements are illustrated in the figures, and a particular ordering or organization of elements or steps has been illustrated, these are non-limiting examples. In certain contexts, two or more elements or steps may be combined into an equivalent element or step, an element or step may be split into two or more equivalent elements or steps, or certain elements or steps may be re-ordered or re-organized or omitted as appropriate, as the explicit illustrated examples are used only for descriptive purposes and are not to be construed as limiting.