Valve assembly with integrated flow sensor controller

An actuator of an environmental control system of a building including a motor and a drive device driven by the motor and configured to drive a valve within a range of positions. The actuator includes one or more printed circuit boards including one or more processing circuits configured to obtain a raw measurement data set from transducers and generate a flow signal based on the raw measurement data set. The flow signal indicates a flow rate of a fluid through a conduit. The one or more processing circuits are configured to determine an actuator position setpoint based on a flow rate setpoint and the flow signal and operate the motor to drive the drive device to the actuator position setpoint. The motor, the drive device, and the one or more printed circuit boards are located within a common device chassis.

BACKGROUND

The present disclosure relates generally to the field of building management system and associated devices and more particularly to the hardware and systems used for controlling fluid flow in a pressure disturbance rejection valve assembly. A pressure disturbance rejection valve assembly includes an onboard electronic controller that is agnostic to system pressure fluctuations. Instead the pressure disturbance rejection valve assembly controls a valve position based on a flow command received from an external device and a flow rate internally determined using a physical measurement from a plurality of transducers.

As building management systems (BMS) become more and more integrated to handle various faults and changing conditions throughout a building, it becomes convenient to create a multi-functional device. By creating a device that allows the user to install one all-encompassing device instead of at least five separate devices (e.g., a transducer, a plurality of processing circuits, an actuator, and a valve) the user saves time and money. It is therefore advantageous to create a pressure disturbance rejection valve assembly that can detect a flow rate, receive an external flow setpoint, and respond to changing conditions in the building.

SUMMARY

One implementation of the present disclosure is an actuator of an environmental control system of a building, according to some embodiments. The actuator includes a motor, according to some embodiments. The actuator includes a drive device driven by the motor and configured to drive a control device within a range of positions, according to some embodiments. The actuator includes a printed circuit board including one or more processing circuits, according to some embodiments. The one or more processing circuits are configured to obtain a raw measurement data set from one or more transducers, according to some embodiments. The one or more processing circuits are configured to generate a flow signal based on the raw measurement data set, according to some embodiments. The flow signal indicates a flow rate of a fluid through a conduit, according to some embodiments. The one or more processing circuits are configured to determine an actuator position setpoint based on a flow rate setpoint and the flow signal, according to some embodiments. The one or more processing circuits are configured to operate the motor to drive the drive device to the actuator position setpoint, according to some embodiments. The motor, the drive device, and the printed circuit board are located within a common device chassis, according to some embodiments.

In some embodiments, the actuator includes a communications circuit. The communications circuit is configured to receive the flow rate setpoint from an external device, according to some embodiments. The communications circuit is configured to provide the flow rate setpoint to the one or more processing circuits, according to some embodiments.

In some embodiments, the one or more processing circuits are configured to determine calibration settings of the one or more transducers. The calibration settings indicate one or more relationships between an output signal of the one or more transducers and the raw measurement data set, according to some embodiments. The flow signal is generated based on the calibration settings, according to some embodiments.

In some embodiments, the one or more transducers are configured to provide an output signal directly indicative of a received signal on the one or more transducers.

In some embodiments, the one or more processing circuits are configured to generate processed data by performing one or more manipulations of the raw measurement data set. The flow signal is generated based on the processed data, according to some embodiments.

In some embodiments, the one or more processing circuits are configured to receive a feedback signal indicating an operating status of the motor. The one or more processing circuits are configured to determine if the operating status of the motor is within a range of expected values, according to some embodiments. The one or more processing circuits are configured to, in response to a determination that the operating status of the motor is not within the range of expected values, initiate a corrective action, according to some embodiments.

In some embodiments, the one or more processing circuits are configured to select an equation for generating the flow signal based on at least one of a type of the one or more transducers, calibration settings of the one or more transducers, or a format of raw measurements of the raw measurement data set. The flow signal is generated based on the selected equation, according to some embodiments.

Another implementation of the present disclosure is an environmental control system of a building, according to some embodiments. The environmental control system includes an actuator, according to some embodiments. The actuator includes a motor, according to some embodiments. The actuator includes a drive device driven by the motor and configured to drive a control device within a range of positions, according to some embodiments. The environmental control system includes a first printed circuit board including a first processing circuit, according to some embodiments. The first processing circuit is configured to obtain a raw measurement data set from one or more transducers, according to some embodiments. The first processing circuit is configured to generate a flow signal based on the raw measurement data set, according to some embodiments. The flow signal indicates a flow rate of a fluid through a conduit, according to some embodiments. The environmental control system includes a second printed circuit board including a second processing circuit, according to some embodiments. The second processing circuit is configured to determine an actuator position setpoint based on a flow rate setpoint and the flow signal, according to some embodiments. The second processing circuit is configured to operate the motor to drive the drive device to the actuator position setpoint, according to some embodiments. The motor, the drive device, the first printed circuit board, and the second printed circuit board are located within a single enclosure, according to some embodiments.

In some embodiments, the environmental control system includes a communications circuit. The communications circuit is configured to receive the flow rate setpoint from an external device, according to some embodiments. The communications circuit is configured to provide the flow rate setpoint to at least one of the first processing circuit or the second processing circuit, according to some embodiments.

In some embodiments, the first processing circuit is configured to determine calibration settings of the one or more transducers, according to some embodiments. The calibration settings indicate one or more relationships between an output signal of the one or more transducers and the raw measurement data set, according to some embodiments. The flow signal is generated based on the calibration settings, according to some embodiments.

In some embodiments, the one or more transducers are configured to provide an output signal directly indicative of a received signal on the one or more transducers.

In some embodiments, the first processing circuit is configured to generate processed data by performing one or more manipulations of the raw measurement data set. The flow signal is generated based on the processed data, according to some embodiments.

In some embodiments, the second processing circuit is configured to receive a feedback signal indicating an operating status of the motor. The one or more processing circuits are configured to determine if the operating status of the motor is within a range of expected values, according to some embodiments. The one or more processing circuits are configured to, in response to a determination that the operating status of the motor is not within the range of expected values, initiate a corrective action, according to some embodiments.

In some embodiments, the first processing circuit is configured to select an equation for generating the flow signal based on at least one of a type of the one or more transducers, calibration settings of the one or more transducers, or a format of raw measurements of the raw measurement data set, according to some embodiments. The flow signal is generated based on the selected equation, according to some embodiments.

Another implementation of the present disclosure is a method for operating a motor of an actuator, according to some embodiments. The method includes obtaining, by one or more processing circuits of a printed circuit board, a raw measurement data set from one or more transducers, according to some embodiments. The method includes generating, by the one or more processing circuits, a flow signal based on the raw measurement data set, according to some embodiments. The flow signal indicates a flow rate of a fluid through a conduit, according to some embodiments. The method includes determining, by the one or more processing circuits, an actuator position setpoint based on a flow rate setpoint and the flow signal, according to some embodiments. The method includes operating, by the one or more processing circuits, a motor of the actuator to drive a drive device of the actuator to the actuator position setpoint, according to some embodiments. The motor, the drive device, and the printed circuit board are located within a common device chassis, according to some embodiments.

In some embodiments, the method includes receiving, by a communications interface, the flow rate setpoint from an external device. The method includes providing, by the communications interface, the flow rate setpoint to at least one of the first processing circuit or the second processing circuit, according to some embodiments.

In some embodiments, the method includes determining, by the one or more processing circuits, calibration settings of the one or more transducers, according to some embodiments. The calibration settings indicate one or more relationships between an output signal of the one or more transducers and the raw measurement data set, according to some embodiments. The flow signal is generated based on the calibration settings, according to some embodiments.

In some embodiments, the one or more transducers are configured to provide an output signal directly indicative of a received signal on the one or more transducers.

In some embodiments, the method includes generating, by the one or more processing circuits, processed data by performing one or more manipulations of the raw measurement data set. The flow signal is generated based on the processed data, according to some embodiments.

In some embodiments, the method includes receiving, by the one or more processing circuits, a feedback signal indicating an operating status of the motor. The method includes determining, by the one or more processing circuits, if the operating status of the motor is within a range of expected values, according to some embodiments. The method includes, in response to a determination that the operating status of the motor is not within the range of expected values, initiating, by the one or more processing circuits, a corrective action, according to some embodiments.

In some embodiments, the method includes selecting, by the one or more processing circuits, an equation for generating the flow signal based on at least one of a type of the one or more transducers, calibration settings of the one or more transducers, or a format of raw measurements of the raw measurement data set. The flow signal is generated based on the selected equation, according to some embodiments.

DETAILED DESCRIPTION

Overview

Before turning to the FIGURES, which illustrate the exemplary embodiments in detail, it should be understood that the disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Referring generally to the FIGURES, various systems for controlling fluid flow in a pressure disturbance rejection valve assembly are shown, according to some embodiments. The pressure disturbance rejection valve assembly includes, at minimum, an electronically-controlled actuator, a valve and a plurality of flow transducers. The flow transducers may include an input/output (I/O) component circuit card assembly, and a measurement circuit. The actuator may include one or more printed circuit boards. Of the plurality, at least one is a flow dedicated printed circuit board (PCB). The flow PCB may include a dedicated microcontroller with an I/O component and a processing component. Of the one or more printed circuit boards, at least one is an actuator dedicated PCB. The actuator PCB may include a dedicated microcontroller with an I/O component, a control component, and a hardware component. In operation, the flow transducers measurement circuit measures a physical property (e.g., pressure, temperature, etc.) of a fluid flowing through the valve, the I/O component circuit card assembly sends this information to the I/O component of the microcontroller on the flow PCB. The I/O component communicates this data to the processing component and the processing component calculates the flow rate of the fluid using a mathematical model of the fluid (e.g. temperature variations). The flow rate can be sent back to the I/O component of the flow PCB. The I/O component of the flow PCB then can send this data to the I/O component of the microcontroller on the actuator PCB. The I/O component of the actuator PCB receives a flow command (e.g., 0%-100%) from an external source (e.g., another controller, a building management system (BMS)) and measured flow readings from the I/O component of the microcontroller on the flow PCB. The I/O component then communicates this data to the control component, which utilizes a control technique (e.g., proportional variable deadband control (PVDC)) to determine an actuator and valve position setpoint. The control component transmits the position setpoint to the hardware component, which rotates a valve stem of the valve to reach the setpoint. The control component constantly monitors the measured flow and the flow setpoint, and adjusts the valve position accordingly in order to minimize the error between the measured flow and the flow setpoint.

The pressure disturbance reaction system includes, at minimum, a flow processing circuit, an actuator processing circuit, and a transducer. The actuator processing circuit may include an input/output (I/O) component circuit assembly, a control component circuit assembly, and a hardware component circuit assembly. The flow processing circuit may include an input/output (I/O) component circuit assembly, a control component circuit assembly, a physical output component, and a hardware component circuit assembly.

Building Management System and HVAC System

Although subplants202-212are shown and described as heating and cooling water for circulation to a building, it is understood that any other type of working fluid (e.g., glycol, CO2, etc.) can be used in place of or in addition to water to serve the thermal energy loads. In other embodiments, subplants202-212may provide heating and/or cooling directly to the building or campus without requiring an intermediate heat transfer fluid. These and other variations to waterside system200are within the teachings of the present disclosure.

Cooling coil334may receive a chilled fluid from waterside system200(e.g., from cold water loop216) via piping342and may return the chilled fluid to waterside system200via piping344. Valve346can be positioned along piping342or piping344to control a flow rate of the chilled fluid through cooling coil334. In some embodiments, cooling coil334includes multiple stages of cooling coils that can be independently activated and deactivated (e.g., by AHU controller330, by BMS controller366, etc.) to modulate an amount of cooling applied to supply air310.

Each of valves346and352can be controlled by an actuator. For example, valve346can be controlled by actuator354and valve352can be controlled by actuator356. Actuators354-356may communicate with AHU controller330via communications links358-360. Actuators354-356may receive control signals from AHU controller330and may provide feedback signals to controller330. In some embodiments, AHU controller330receives a measurement of the supply air temperature from a temperature sensor362positioned in supply air duct312(e.g., downstream of cooling coil334and/or heating coil336). AHU controller330may also receive a measurement of the temperature of building zone306from a temperature sensor364located in building zone306.

Each of building subsystems428may include any number of devices, controllers, and connections for completing its individual functions and control activities. HVAC subsystem440may include many of the same components as HVAC system100, as described with reference toFIGS. 1-3. For example, HVAC subsystem440may include and number of chillers, heaters, handling units, economizers, field controllers, supervisory controllers, actuators, temperature sensors, and/or other devices for controlling the temperature, humidity, airflow, or other variable conditions within building10. Lighting subsystem442may include any number of light fixtures, ballasts, lighting sensors, dimmers, or other devices configured to controllably adjust the amount of light provided to a building space. Security subsystem438may include occupancy sensors, video surveillance cameras, digital video recorders, video processing servers, intrusion detection devices, access control devices and servers, or other security-related devices.

Still referring toFIG. 4, BMS controller366is shown to include a communications interface407and a BMS interface409. Interface407may facilitate communications between BMS controller366and external applications (e.g., monitoring and reporting applications422, enterprise control applications426, remote systems and applications444, applications residing on client devices448, etc.) for allowing user control, monitoring, and adjustment to BMS controller366and/or subsystems428. Interface407may also facilitate communications between BMS controller366and client devices448. BMS interface409may facilitate communications between BMS controller366and building subsystems428(e.g., HVAC, lighting security, lifts, power distribution, business, etc.).

Memory408(e.g., memory, memory unit, storage device, etc.) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present application. Memory408can be or include volatile memory or non-volatile memory. Memory408may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present application. According to some embodiments, memory408is communicably connected to processor406via processing circuit404and includes computer code for executing (e.g., by processing circuit404and/or processor406) one or more processes described herein.

In some embodiments, BMS controller366is implemented within a single computer (e.g., one server, one housing, etc.). In various other embodiments BMS controller366can be distributed across multiple servers or computers (e.g., that can exist in distributed locations). Further, whileFIG. 4shows applications422and426as existing outside of BMS controller366, in some embodiments, applications422and426can be hosted within BMS controller366(e.g., within memory408).

Building subsystem integration layer420can be configured to manage communications between BMS controller366and building subsystems428. For example, building subsystem integration layer420may receive sensor data and input signals from building subsystems428and provide output data and control signals to building subsystems428. Building subsystem integration layer420may also be configured to manage communications between building subsystems428. Building subsystem integration layer420translate communications (e.g., sensor data, input signals, output signals, etc.) across a plurality of multi-vendor/multi-protocol systems.

Pressure Disturbance Rejection Valve Assembly

Referring now toFIG. 5, a block diagram of a pressure disturbance rejection valve assembly500is shown, according to some embodiments. Valve assembly500may be used in HVAC system100, waterside system200, airside system300, or BMS400, as described with reference toFIGS. 1-4. Valve assembly500is shown to include an actuator502coupled to a control device504. For example, actuator502may be a damper actuator, a valve actuator, a fan actuator, a pump actuator, or any other type of actuator that can be used in an HVAC system or BMS. In various embodiments, actuator502may be a linear actuator (e.g., a linear proportional actuator), a non-linear actuator, a spring return actuator, a non-spring return actuator, a capacitive return actuator, or a non-capacitive return actuator.

Control device504may be any type of control device (e.g., a valve) configured to control an environmental parameter in an HVAC system, including, but not limited to, a 2-way or 3-way two position electric motorized valve, a ball isolation valve, a floating point control valve, an adjustable flow control device, or a modulating control valve. In some embodiments, control device504may regulate the flow of a fluid through a conduit, pipe, or tube (e.g., conduit512) in a waterside system (e.g., waterside system200, shown inFIG. 2). Conduit512may include upstream conduit section506and downstream conduit section508. In other embodiments, control device504may regulate the flow of air through a duct in an airside system (e.g., airside system300, shown inFIG. 3).

In some embodiments, actuator502and control device504are located within a common integrated device chassis or housing. In short, actuator502and control device504may not be packaged as separate devices, but as a single device. Reducing the number of devices in an HVAC system may provide numerous advantages, most notably in time and cost savings during the installation process. Because it is not necessary to install actuator502and control device504as separate devices and then make a connection between them, technicians performing the installation may require less specialized training and fewer tools. Other advantages of a single device may include simplification of control and troubleshooting functions. However, in some embodiments, actuator502and control device504are packaged as separate devices that may be communicably coupled via a wired or a wireless connection.

Still referring toFIG. 5, a plurality of transducers510are shown to be disposed within upstream conduit section506. Transducers510may be configured to measure any type of physical property of the fluid passing through conduit512, and more specifically, the fluid entering control device504. The physical property may be but is not limited to: temperature, pressure, displacement, electric potential, resistance, electric current, light intensity, or ultrasonic time of flight. Ultrasonic time of flight is a length of time it takes for an ultrasonic wave to travel through the fluid. In some embodiments, the measurement of the physical property may be a differential measurement such that it consists of a difference between two or more measurements. Transducers510may be any type of device (e.g., ultrasonic transducer, paddle-wheel transducer, pitot tube, pressure transducer, piezoelectric transducer, chemical transducer, photovoltaic transducer, turbine flow transducer, vortex transducer, venturi transducer, pitot tubes, calorimetrics transducers, electromagnetic transducers, Doppler transducers, thermal transducers, Coriolis transducers, etc.) configured to collect the physical measurement using any applicable method. In some embodiments, transducers510are configured to provide an output signal directly indicative of a force exerted on transducers510by the fluid. The force exerted on transducers510may depend on the flow rate or flow velocity of the fluid as well as properties of the fluid such as density, viscosity, specific gravity, etc. Accordingly, additional calculations may be needed to convert the output of transducers510into a flow rate. In some embodiments, transducers510are a plurality of temperature transducers (e.g. a thermocouple) that collects measurements pertinent to the principles of King's Law. According to King's Law, the heat transfer from a heated object exposed to a moving fluid is a function of the velocity of the fluid. King's Law devices have several features, including very high sensitivity at low flow rates and measurement of the fluid temperature (which may be useful for control purposes), although they have decreased sensitivity at high flow rates.

In other embodiments, transducers510are a plurality of ultrasonic transducers that collect measurements pertinent to the Strouhal number. The Strouhal number is a dimensionless value useful for characterizing oscillating flow dynamics. An ultrasonic transducer measures the acoustic detection of vortices in fluid caused when the fluid flows past a cylindrically-shaped obstruction. The vibrating frequency of the vortex shedding is correlated to the flow velocity. Vortex-shedding devices have good sensitivity over a range of flow rates, although they require a minimum flow rate in order to be operational.

The plurality of transducers may be located in any location along conduit512, including before control device504, after control device504, or any other location. In some embodiments, each member of the plurality may take a measurement, and the physical measurement may be made up of a plurality of measurements. In some embodiments, transducers510are a ring shaped plurality of transducers that wraps around conduit512. The ring can include two or more transducers located opposite to one another. In additional embodiments, transducers510are a single transducer. The single transducer may be used to measure a physical property of the fluid. For example, the single transducer may be a pressure transducer (e.g., pitot tube) used to collect a differential pressure measurement.

Transducers510may be communicably coupled to actuator502. For example, transducers510may be coupled via wired or wireless connection for the purpose of the transmission of the raw measurement data set. As defined herein, a raw measurement can described an unadjusted measurement from a transducer that may or may not be proportional to a flow rate. Specifically, raw measurements may be direct (i.e., unprocessed) measurements from transducers that do not account for fluid characteristics (e.g., density, specific gravity, etc.), configuration settings of the transducer, or other considerations that may affect an association between the raw measurements and a flow rate. In some embodiments, the raw measurement data set may be transmitted as an analog signal. Specifically, the raw measurement data set may be a set of voltage signals, current signals, etc. outputted by transducers510.

It should be noted that transducers510are not a component of a sensor. Rather, transducers510are independent components that can output raw measurements (e.g., in the form of raw voltage or current signals) directly to actuator502. In traditional systems, transducers510may be a part of a sensor (e.g., a flow sensor) that account for characteristics of a fluid to convert the raw measurements into a flow proportionate value. As described herein, a flow proportionate value can refer to a value that is proportional to flow and is determined by manipulating raw measurements from transducers based on characteristics of a fluid measured by the transducers and/or other factors that can affect interpretation of the raw measurements. For example, a flow proportionate value may be a voltage value that is calculated based on raw measurements gathered by transducers510and manipulated based on characteristics of a fluid (e.g., density, viscosity, specific gravity, etc.) passing through conduit512or other calibration data for transducers510. These traditional systems thereby require some processing capabilities within the sensor to convert the raw measurements into the flow proportionate value. However, as shown inFIG. 5, actuator502can directly receive measurements from transducers510to calculate flow proportionate values, thus eliminating the need for complex sensors with processing components in valve assembly500. A structure of traditional sensors and comparisons to the present application are described in detail below with reference toFIGS. 13-15.

A flow proportionate value may be directly proportional to flow rate and can be used to calculate flow rate without knowledge of any intensive properties of the fluid being measured (e.g., density, specific gravity, etc.). For example, a flow proportionate voltage signal may range from a minimum voltage Vmin(e.g., 0V, 2V, etc.) to a maximum voltage Vmax(e.g., 10V, 12V, etc.), where a value of Vmincorresponds to a minimum flow rate Flowmin(e.g., zero flow, a non-zero minimum flow), a value of Vmaxcorresponds to a pre-established maximum flow rate Flowmax, and any value between Vminand Vmaxcorresponds directly to a flow rate between Flowminand Flowmax. Conversely, a flow disproportionate value may include raw transducer measurements that are not proportional to flow rate (e.g., time of flight) or raw transducer measurements that cannot be converted to flow rate without knowledge of an intensive property of the fluid being measured.

Accordingly, it should be understood that the term “flow proportionate value” as used herein refers to any value that is proportional to the flow rate where the proportionality factor is not dependent on an intensive property of the fluid (e.g., density, specific gravity, etc). Accordingly, an actual flow rate can be calculated directly from a flow proportionate value without compensating for any fluid-specific properties. Conversely, the term “flow disproportionate value” refers to any value that is either not proportional to the flow rate (e.g., time of flight measurements) or cannot be used to calculate a flow rate without knowledge of any intensive properties of the fluid such as density, viscosity, specific gravity, and the like (e.g., measurements from a pressure transducer). Accordingly, an actual flow rate cannot be calculated directly from a flow disproportionate value without either adjusting for a fluid-specific property such as density or using an equation that amounts to more than mere multiplication or division by a fluid-independent proportionality factor.

Referring now toFIG. 6A, a block diagram of another pressure disturbance rejection valve assembly600is shown using two printed circuit boards within one common device chassis, according to some embodiments. Valve assembly600may be used in HVAC system100, waterside system200, airside system300, or BMS400, as described with reference toFIGS. 1-4. Valve assembly600may represent a more detailed version of valve assembly500. For example, valve assembly600is shown to include actuator602, which may be identical or substantially similar to actuator502in valve assembly500. Actuator602may be configured to operate equipment604. Equipment604may include any type of system or device that can be operated by an actuator (e.g., a valve, a damper). In an exemplary embodiment, actuator602and equipment604(e.g., a valve) are packaged within a common device chassis. In some embodiments, various circuits/circuit boards of actuator602(e.g., flow sensor printed circuit board636, actuator printed circuit board606) are included in a single printed circuit board as described in greater detail below with reference toFIG. 7A. In some embodiments, functionality of flow sensor printed circuit board636and actuator printed circuit board606are included in a single processing circuit as described in greater detail below with reference toFIG. 7B.

Actuator602is shown to include an actuator printed circuit board606. Actuator printed circuit board606may be any sort of printed circuit board (PCB) such as a single sided PCB, a double sided PCB, a multilayer PCB, a rigid PCB, a flex PCB, a rigid-flex PCB, or two or more combinations. Actuator printed circuit board606is further shown to include an actuator processing circuit607communicably coupled to motor626. Actuator processing circuit607may be any type of circuit such as an integrated circuit, a chip, or a microcontroller unit (MCU). In some embodiments, motor626is a brushless DC (BLDC) motor. Actuator processing circuit607is shown to include an actuator processor608, actuator memory610, and a main actuator controller612. Actuator processor608can be a general purpose or specific purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable processing components. Actuator processor608can be configured to execute computer code or instructions stored in actuator memory610or received from other computer readable media (e.g., CDROM, network storage, a remote server, etc.)

Actuator memory610may include one or more devices (e.g., memory units, memory devices, storage devices, etc.) for storing data and/or computer code for completing and/or facilitating the various processes described in the present disclosure. Actuator memory610may include random access memory (RAM), read-only memory (ROM), hard drive storage, temporary storage, non-volatile memory, flash memory, optical memory, or any other suitable memory for storing software objects and/or computer instructions. Actuator memory610may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. Actuator memory610can be communicably connected to actuator processor608via actuator processing circuit607and may include computer code for executing (e.g., by actuator processor608) one or more processes described herein. When actuator processor608executes instructions stored in actuator memory610, actuator processor608generally configures actuator602(and more particularly actuator processing circuit607) to complete such activities.

Actuator printed circuit board606is further shown to include an actuator power supply circuit614. Actuator power supply circuit614may be an unregulated power supply, a linear regulated power supply, a switching power supply, or a ripple regulated power supply. In some embodiments, actuator power supply circuit614is a wired connection between an exterior power supply and actuator processing circuit607. Actuator power supply circuit614may be coupled to actuator processing circuit through a wired connection. Through the couple, actuator power supply circuit614may provide power to actuator processing circuit607. Actuator power supply circuit614circuit may provide either AC voltage or DC voltage power to actuator processing circuit607. In some embodiments, actuator power supply circuit614may be a battery that is coupled to the actuator processing circuit607. In short, actuator power supply circuit614may provide power through a chemical reaction that creates a voltage potential.

Still referring toFIG. 6A, actuator processing circuit607may be configured to output a pulse width modulated (PWM) DC motor command632to control the speed of the motor. Motor626may be configured to receive a three-phase PWM voltage output (e.g., phase A, phase B, phase C) from motor drive inverter624. The duty cycle of the PWM voltage output may define the rotational speed of motor626and may be determined by actuator processing circuit607. Actuator processing circuit607may increase the duty cycle of the PWM voltage output to increase the speed of motor626and may decrease the duty cycle of the PWM voltage output to decrease the speed of motor626.

Motor626may be coupled to drive device628. Drive device628may be a drive mechanism, a hub, or other device configured to drive or effectuate movement of a HVAC system component (e.g., equipment604). For example, drive device628may be configured to receive a shaft of a damper, a valve, or any other movable HVAC system component in order to drive (e.g., rotate) the shaft. In some embodiments, actuator602includes a coupling device configured to aid in coupling drive device628to the movable HVAC system component. For example, the coupling device may facilitate attaching drive device628to a valve or damper shaft.

Main actuator controller612may be configured to receive external data618(e.g., flow rate setpoints, position setpoints, speed setpoints, etc.) from communications circuit620and flow signals646from a flow sensor processing circuit638. In some embodiments, main actuator controller612receives data from additional sources. For example, motor current sensor622may be configured to measure the electric current provided to motor626. Motor current sensor622may generate a feedback signal indicating the motor current630and may provide this signal to main actuator controller612within actuator processing circuit607. Based on the feedback signal, main actuator controller612can determine if motor commands632is resulting in expected operation of motor626. In other words, main actuator controller612can determine if an operating status of motor626is reflective of expected values. The expected values can be include any value or values that are acceptable values of the feedback signal. In some embodiments, the expected values are a range of values that are appropriate for the feedback signal. If the current indicated by the feedback signal is representative of expected values, main actuator controller612may continue standard operations. However, if the current indicated by the feedback signal is not representative of expected values, main actuator controller612may initiate a corrective action. In some embodiments, the feedback signal indicates other measurements associated with motor626and/or motor drive inverter624. For example, the feedback signal may indicate a voltage, a resistance, a power consumption value, etc.

Corrective actions may include any actions that address unexpected values of the feedback signal (i.e., motor current630). For example, main actuator controller612may modify motor commands632to adjust operation of motor drive inverter624. In effect, main actuator controller612may be recalibrated to account for changes in how motor626and/or motor drive inverter624operate based on the feedback signal. If motor current630is lower than expected, main actuator controller612may increase the duty cycle associated with motor commands632to increase rotational speed of motor626. As another example of a corrective action, main actuator controller612may schedule motor626for repair. Inaccurate values of the feedback signal (i.e., inaccurate values of motor current630) may indicate some degradation of motor626has occurred. As such, main actuator controller612can initiate a corrective action to reduce effects of the degradation. In general, main actuator controller612can initiate any corrective action to address determinations of inaccuracies in feedback signals. Advantageously, by allowing main actuator controller612to initiate corrective actions, further functionality is included in actuator602, thereby reducing/eliminating additional components needed in valve assembly600.

Actuator602is further shown to include a communications circuit620. Communications circuit620may be a wired or wireless communications link and may use any of a variety of disparate communications protocols (e.g., BACnet, LON, WiFi, Bluetooth, NFC, TCP/IP, etc.). In some embodiments, communications circuit620is an integrated circuit, chip, or microcontroller unit (MCU) configured to bridge communications actuator602and external systems or devices. In some embodiments, communications circuit620is the Johnson Controls BACnet on a Chip (JBOC) product. For example, communications circuit620can be a pre-certified BACnet communication module capable of communicating on a building automation and controls network (BACnet) using a master/slave token passing (MSTP) protocol. Communications circuit620can be added to any existing product to enable BACnet communication with minimal software and hardware design effort. In other words, communications circuit620provides a BACnet interface for the pressure disturbance rejection valve assembly600. Furthermore, details regarding the JBOC product are disclosed in U.S. patent application Ser. No. 15/207,431 filed Jul. 11, 2016, the entire disclosure of which is incorporated by reference herein.

Communications circuit620may also be configured to support data communications within actuator602. In some embodiments, communications circuit620may receive internal actuator data616from main actuator controller612. For example, internal actuator data616may include the sensed motor current630, a measured or calculated motor torque, the actuator position or speed, configuration parameters, end stop locations, stroke length parameters, commissioning data, equipment model data, firmware versions, software versions, time series data, a cumulative number of stop/start commands, a total distance traveled, an amount of time required to open/close equipment604(e.g., a valve), or any other type of data used or stored internally within actuator602. In some embodiments, communications circuit620may transmit external data618to main actuator controller612. External data618may include, for example, flow rate setpoints, position setpoints, speed setpoints, control signals, configuration parameters, end stop locations, stroke length parameters, commissioning data, equipment model data, actuator firmware, actuator software, or any other type of data which can be used by actuator602to operate the motor626and/or drive device628. For example, external data618may include a flow rate setpoint indicating a desired flow rate through a conduit in order to affect a desired environmental condition.

In some embodiments, external data618is a DC voltage control signal. Actuator602can be a linear proportional actuator configured to control the position of drive device628according to the value of the DC voltage received. For example, a minimum input voltage (e.g., 0.0 VDC) may correspond to a minimum rotational position of drive device628(e.g., 0 degrees, −5 degrees, etc.), whereas a maximum input voltage (e.g., 10.0 VDC) may correspond to a maximum rotational position of drive device628(e.g., 90 degrees, 95 degrees, etc.). Input voltages between the minimum and maximum input voltages may cause actuator602to move drive device628into an intermediate position between the minimum rotational position and the maximum rotational position. In other embodiments, actuator602can be a non-linear actuator or may use different input voltage ranges or a different type of input control signal (e.g., AC voltage or current) to control the position and/or rotational speed of drive device628.

In some embodiments, external data618is an AC voltage control signal. Communications circuit620may be configured to transmit an AC voltage signal having a standard power line voltage (e.g., 120 VAC or 230 VAC at 50/60 Hz). The frequency of the voltage signal can be modulated (e.g., by main actuator controller612) to adjust the rotational position and/or speed of drive device628. In some embodiments, actuator602uses the voltage signal to power various components of actuator602. Actuator602may use the AC voltage signal received via communications circuit620as a control signal, a source of electric power, or both. In some embodiments, the voltage signal is received from a power supply line that provides actuator602with an AC voltage having a constant or substantially constant frequency (e.g., 120 VAC or 230 VAC at 50 Hz or 60 Hz). Communications circuit620may include one or more data connections (separate from the power supply line) through which actuator602receives control signals from a controller or another actuator (e.g., 0-10 VDC control signals).

Still referring toFIG. 6A, actuator602is shown to include a flow sensor printed circuit board636. Flow sensor printed circuit board636may be any sort of printed circuit board (PCB) such as a single sided PCB, a double sided PCB, a multilayer PCB, a rigid PCB, a flex PCB, a rigid-flex PCB, or two or more combinations. Flow sensor printed circuit board636is further shown to include a flow sensor processing circuit638communicably coupled to main actuator controller612and a plurality of transducers634. Flow sensor processing circuit638may be any type of circuit such as an integrated circuit, a chip, or a microcontroller unit (MCU). Flow sensor processing circuit638is shown to include a flow sensor processor640and a flow sensor memory642. Flow sensor processor640can be a general purpose or specific purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable processing components. Flow sensor processor640can be configured to execute computer code or instructions stored in flow sensor memory642or received from other computer readable media (e.g., CDROM, network storage, a remote server, etc.)

Flow sensor memory642may include one or more devices (e.g., memory units, memory devices, storage devices, etc.) for storing data and/or computer code for completing and/or facilitating the various processes described in the present disclosure. Flow sensor memory642may include random access memory (RAM), read-only memory (ROM), hard drive storage, temporary storage, non-volatile memory, flash memory, optical memory, or any other suitable memory for storing software objects and/or computer instructions. Flow sensor memory642may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. Flow sensor memory642may be communicably connected to flow sensor processor640via flow sensor processing circuit638and may include computer code for executing (e.g., by flow sensor processor640) one or more processes described herein. When flow sensor processor640executes instructions stored in flow sensor memory642, flow sensor processor640generally configures flow sensor processing circuit638to complete such activities.

Flow sensor processing circuit638may be further configured to receive raw measurement data set648from transducers634. It should be appreciated that raw measurement data set648may not include any actual flow rates. Rather, raw measurement data set648can include raw measurements from transducers634that can be used to calculate flow proportionate values and thereby flow rates and/or may calculate the flow rates directly based on the raw measurements. As described in greater detail below, flow sensor processing circuit638can be configured to calculate the flow rates based on raw measurement data set648. Advantageously, calculating flow rates by flow sensor processing circuit638reduces complexity of transducers634and/or of other sensors in valve assembly600. In particular, transducers634may not be required to include processing circuits for parsing through raw measurements. Further, additional sensors may not be required in valve assembly600to process measurements taken by transducers634. Instead, flow sensor processing circuit638(and therefore actuator602) can handle processing of the raw measurements, thereby reducing costs, a number of components, and overall complexity of valve assembly600.

Flow sensor memory642is shown to include a flow signal generator650. Flow signal generator650can be configured to process raw measurement data set648to determine a flow signal646. Based on raw measurements (e.g., voltage, current, etc.) included in raw measurement data set648, flow signal generator650can calculate a flow rate of a fluid (e.g., of water, of air, etc.) through a conduit of valve assembly600. Specifically, flow signal generator650may calculate a flow proportionate value based on the raw measurements and determine the flow signal based on the flow proportionate value. For example, if the raw measurements include voltages indicative of a pressure exerted on transducers634, flow signal generator650can determine a value proportional to a flow rate based on the raw measurements, a density of the fluid, some equation that accounts for calibration of transducers634, internal resistances of wires providing the voltages, etc. As the raw measurements provided by transducers634may not be directly proportional to the flow rate, flow signal generator650should perform said processing to calculate a flow proportionate value to determine the flow signal.

In some embodiments, flow signal generator650requires additional information beyond the raw measurements of raw measurement data set648to calculate the flow rate. For example, to calculate the flow rate indicated by flow signal646, flow signal generator650can utilize information regarding transducers634such as a brand of transducers634, calibration settings of transducers634, spacing of transducers634, etc. Based on information regarding transducers634, flow signal generator650can utilize equations and/or other relationships to calculate a flow proportionate value and thereby the flow rate. In this way, flow signal generator650can allow actuator602to calculate flow rates as compared to requiring complex sensors that include transducers634and processing components and/or requiring incorporation of additional components to valve assembly600. Flow signal generator650is described in greater detail below with reference toFIG. 6B. It should be appreciated that flow signal generator650is shown as an example of a component that flow sensor memory642may include. Flow sensor memory642may include additional components and/or other components rather than flow signal generator650. In general, flow sensor memory642can include any components necessary for generating flow signal646.

Flow sensor printed circuit board636is also shown to include a flow sensor power supply circuit644. Flow sensor power supply circuit644may be an unregulated power supply, a linear regulated power supply, a switching power supply, or a ripple regulated power supply. In some embodiments, flow sensor power supply circuit644is a wired connection between an exterior power supply and flow sensor processing circuit638. Flow sensor power supply circuit644may be coupled to flow sensor processing circuit638through a wired connection. Flow sensor power supply circuit644may be configured to provide power to flow sensor processing circuit638. Flow sensor power supply circuit644may provide either AC voltage or DC voltage power to flow sensor processing circuit638. In some embodiments, flow sensor power supply circuit644may be a battery that is coupled to the flow sensor processing circuit638. In short, flow sensor power supply circuit644may provide power through a chemical reaction that creates a voltage potential.

Valve assembly600may include the transducers634. Transducers634may be identical or substantially similar to transducers510in valve assembly500. Transducers634may be communicably coupled to flow sensor processing circuit638. Transducer634may be configured to take a measurement of a physical property of the fluid flowing through equipment604and provide raw measurement data set648to flow sensor processing circuit638. In some embodiments, raw measurement data set648may be output as an analog output signal. For example, the analog output signal can be represented by a voltage, current, or resistance. In general, transducers634can provide raw measurement data set648including raw measurements to actuator602for processing.

In some embodiments, actuator602, flow sensor processing circuit638and actuator processing circuit607are located within a common device chassis or housing. In short, actuator602, flow sensor processing circuit638, and actuator processing circuit607may not be packaged as separate devices, but as a single device. In some embodiments, additional components (e.g., equipment604, transducers634, etc.) are packaged in the single device. Reducing the number of devices in an HVAC system may provide numerous advantages, most notably in time and cost savings during the installation process. Because it is not necessary to install actuator602, flow sensor processing circuit638, and actuator processing circuit607as separate devices, technicians performing the installation may require less specialized training and fewer tools. Other advantages include integrated calibration. Because actuator processing circuit607is communicably coupled to flow sensor processing circuit638and actuator602, actuator processing circuit607may include a set of instructions to automatically calibrate the device through various setpoints of actuator602and flow signal646. By having an all-in one device that can calibrate itself, an annual calibration is not required. This saves time and cost. However, in some embodiments, actuator602, flow sensor processing circuit638, and actuator processing circuit607are packaged as separate devices that may be communicably coupled via a wired or a wireless connection. In some embodiments, flow sensor printed circuit board636and actuator printed circuit board606are within separate enclosures.

Referring now toFIG. 6B, flow signal generator650ofFIG. 6Ais shown in greater detail, according to some embodiments. As described above with reference toFIG. 6A, flow signal generator650can be configured to generate flow signal646based on raw measurement data set648. Flow signal generator650is shown to include various components which are described in detail below. Each component of flow signal generator650is shown purely for sake of example. Flow signal generator650may include less, more, and/or different components than as shown inFIG. 6B. In some embodiments, components of flow signal generator650are implemented as different components of flow sensor memory642. In general, flow signal generator650and/or flow sensor memory642can include any components necessary for generating flow signal646based on raw measurement data set648.

Flow signal generator650is shown to include a transducer identifier652. Transducer identifier652can be configured to identify what types of transducers are included in transducers634and/or other information regarding transducers634. For example, transducer identifier652may identify brands of transducers634, specific models (e.g., as given by model numbers) of transducers634, specific components of transducers634(e.g., components used to sense pressure and/or other measurements describing flow), etc. The information identified by transducer identifier652can be utilized to determine various information regarding raw measurement data set648. For example, raw measurement manipulator658may utilize the information identified by transducer identifier652to determine an expected format (e.g., voltage, current, resistance, etc.) that the raw measurements of raw measurement data set648may be provided in based on a model of transducers634. In this way, transducer identifier652can reduce/eliminate a need for flow signal generator650to process the raw measurements to determine the format. The identified information regarding transducers634can be useful for other purposes such as determining initial calibration settings of transducers634, how transducers634may be installed in a conduit, etc.

Flow signal generator650is also shown to include a calibration sensor654. Calibration sensor654can be configured to determine calibration settings of transducers634. Calibration settings can indicate relationships between transducers634and the raw measurements included in raw measurement data set648. Different transducers of transducers634may have different calibration settings (e.g., different relationships between sensed voltage and flow) that need to be known in order to accurately convert the raw measurements into a flow rate. Without knowledge of the calibration settings, flow signal generator650may otherwise calculate an inaccurate flow rate as a result of incorrect assumptions regarding how transducers634are calibrated. To mitigate said effects, calibration sensor654can determine calibration settings of transducers634that can be utilized to accurately calculate the flow rate respective of how transducers634are calibrated.

To determine the calibration settings, calibration sensor654can utilize various approaches. In some embodiments, calibration sensor654collects raw measurements provided by transducers634(e.g., as provided in raw measurement data set648) and estimates calibration settings based on the raw measurements. In some embodiments, calibration sensor654utilizes other information to determine the calibration settings. For example, calibration sensor654can utilize model numbers of transducers634identified by transducer identifier652to determine initial calibration settings indicated by a manufacturer(s). In some embodiments, calibration sensor654determines the calibration settings via a different approach.

Still referring toFIG. 6B, flow signal generator650is shown to include a spacing sensor656. Spacing sensor656can be configured to determine a distance between individual transducers of transducers634. For example, if transducers634includes two transducers, spacing sensor656can determine a distance between the two transducers (e.g., as measured in inches, centimeters, meters, etc.). Distances between transducers634can be particularly useful in calculating the flow rate. For example, the distances between transducers634can be utilized in calculating a time of flight of ultrasonic waves through a fluid. The distances can be used to determine the flow rate based on the distance and a time between when an ultrasonic wave is emitted and received by different transducers.

Flow signal generator650is also shown to include a raw measurement manipulator658. Raw measurement manipulator658can be configured to generate processed data based on raw measurement data set648. Raw measurement manipulator658can aggregate raw measurements, determine formats of the raw measurements, combine raw measurements, and/or can perform any other appropriate manipulations of the raw measurements included in raw measurement data set648. For example, raw measurement manipulator658can identify a format of the raw measurements indicated by raw measurement data set648and group the raw measurements based on the formats. The formats can include any various format which transducers634can provide raw measurements of flow rates. For example, the raw measurements may be formatted as voltages or currents. Identification of the formats of the raw measurements can be critical in ensuring correct equations are utilized to determine the flow rate indicated by flow signal646. In some embodiments, raw measurement manipulator658extracts the formats directly from raw measurement data set648. In some embodiments, raw measurement manipulator658utilizes information determined by other components of flow signal generator650to determine the formats. For example, raw measurement manipulator658can determine expected data formats based on models of transducers634identified by transducer identifier652. Based on the formats, raw measurement manipulator658can group the raw measurements such that it is easier for other components of flow signal generator650to calculate flow proportionate values and/or flow rates.

In some embodiments, raw measurement manipulator658organizes the raw measurements chronologically. As raw measurements are received from transducers634, they can be sorted by raw measurement manipulator658such that the measurements are stored in chronological order, associated with a timestamp indicating a time when the measurements were gathered and/or received, and/or organized in some other fashion. Chronological sorting of the raw measurements can be useful in various applications such as tracking the flow rates over time, calculating the flow rate based on a distance between transducers634and the amount of time between measurements, etc.

In some embodiments, raw measurement manipulator658performs other manipulations on the raw measurements of raw measurement data set648to generate processed data (e.g., flow proportionate values) that can be utilized to calculate the flow rate. For example, raw measurement manipulator658can identify measurements that may be inaccurate (e.g., a raw voltage measurement twice as large as any other measurements) and purge said data from a data set used to calculate the flow rate. Inaccurate measurements may result from faulty transducers, data corruption in transit between transducers634and actuator602, and/or other various sources. It should be appreciated that raw measurement manipulator658can perform any manipulations on the raw measurements that may be helpful in calculating the flow rate. In a sense, the manipulations performed by raw measurement manipulator658can be considered as processing of raw measurement data set648. As received, raw measurement data set648may include measurements that are not directly usable to calculate the flow rate. As such, raw measurement manipulator658can be configured to perform processing operations (i.e., manipulations) on raw measurement data set648to generate processed data that is usable to calculate the flow rate. In some embodiments, the processed data is generated in a machine-readable format (e.g., binary representation that can be interpreted by computers) for further calculations.

Flow signal generator650is shown to include an equation selector660. Equation selector660can select one or more equations to utilize in calculating the flow rate based on information determined by other components of flow signal generator650. In some embodiments, equation selector660and/or a different component of flow sensor memory642(e.g., a database component) may store equations that can be used to calculate the flow rate. Said equations can utilize various measurements gathered by transducers634to calculate the flow rate. As some examples, a first equation may relate measurements of current over time to the flow rate, a second equation may relate voltage and resistance measurements to the flow rate, a third equation may relate a time of flight of an ultrasonic signal through a substance to the flow rate, etc. In the case of the third equation, the time of flight may be determined based on, for example, spikes in the voltage/current provided by transducers634that indicate when an ultrasonic signal is transmitted by one transducer634and received by another transducer634. In some embodiments, an equation selected by equation selector660is augmented to account for characteristics of a fluid measured by transducers634. For example, if transducers634are pressure transducers that output a voltage/current respective of a pressure exerted on transducers634, the equation may be augmented based on a density of the fluid to ensure an accurate flow proportionate value and/or accurate flow signal is calculated. Specifically, in the example, small increases in flow for a more dense fluid may result in larger pressure changes as compared to small increases in flow for a less dense fluid. Accordingly, the equation can be manipulated to account for characteristics of a fluid to ensure that an accurate flow proportionate value is calculated.

The equations selected by equation selector660can be received/generated from a variety of sources. The equations may be inputted by a user, generated based on measurements over time, received from a manufacturer of transducers634, etc. It should be appreciated that the equations can include mathematical equations, mappings, models (e.g., mathematical models, artificial intelligence models, etc.), and/or any other relationship that can be used to calculate flow rates based on measurements. In some embodiments, the equations are stored by an external entity. For example, the equations may be stored by a cloud database. In this case, equation selector660can request and receive the equation from the external entity (e.g., via communications circuit620).

Equation selector660can select an appropriate equation(s) based on information determined by other components of flow signal generator650. For example, equation selector660may utilize model numbers of transducers634identified by transducer identifier652to select an equation provided by a manufacturer. As another example, equation selector660can select an equation based on data formats identified by raw measurement manipulator658. In some embodiments, equation selector660may select a generalized equation and augment the equation based on information determined by components of flow signal generator650. For example, equation selector660may select a general equation relating voltage to flow rates and augment the equation (e.g., by changing constants and scaling factors of the equation) based on calibration settings identified by calibration sensor654, characteristics of a measured fluid, etc. In this way, generalized equations can be augmented to be reflective of current calibration settings of transducers634. In some embodiments, equation selector660can select any of a multitude of different equations based on an identity of transducers634that are feeding data to actuator602. In some embodiments, equation selector660provides the selected/augmented equation to a flow rate calculator662.

Flow signal generator650is shown to include flow rate calculator662. Flow rate calculator662can be configured to calculate a flow rate of a substance (e.g., a liquid, air, etc.) through a conduit. In some embodiments, flow rate calculator662calculates a flow proportionate value used to calculate the flow rate. Based on the equation selected by equation selector660, flow rate calculator662can provide the raw measurements of raw measurement data set648as input to calculate the flow rate of the substance. For example, if the raw measurements are known to indicate a time of flight of an ultrasonic signal through the substance, flow rate calculator662may utilize an equation to calculate the difference between an upstream and a downstream signal and determine the flow rate based on the difference. In some embodiments, flow rate calculator662utilizes multiple equations to determine the flow rate. Based on an output of the equation(s), flow rate calculator662can generate flow signal646.

As an example of how flow rate calculator662can calculate the flow rate, consider a situation where raw measurement data set648includes raw measurements taken by an upstream ultrasonic flow transducer and a downstream ultrasonic flow transducer. In this situation, the flow rate can be calculated based on a time of flight indicated by a time difference between upstream and downstream signal times. Said time difference may be determined based on when voltage and/or current signals greater than a predefined threshold are received by flow signal generator650. The upstream signal time Tupand the downstream signal time Tdowncan be included in/indicated by raw measurement data set648. Tupand Tdowncan be represented by flow rate calculator662via the following equations:

Tup=Lc+vTdown=Lc-v
where L is a distance between receiving and transmitting transducers, c is a speed of sound, and v is the flow rate. Based on the above equations, flow rate calculator662can represent the time of flight ΔT as:

Δ⁢⁢T=Tdown-Tup=2⁢Lvc2-v2
The above equation can be augmented by flow rate calculator662to solve for the flow rate as:

v=L2×(1Tup-1Tdown)=L2×(Tdown-TupTdown⁢Tup)=L2×(Δ⁢⁢TTdown⁢Tup)
which assumes an inclination angle between the transducers is perpendicular. In some embodiments, the above equations are selected by equation selector660and provided to flow rate calculator662. In this way, flow rate calculator662can calculate the flow rate based on raw measurement data set648.

Flow signal646can include the flow rate calculated by flow rate calculator662. In some embodiments, flow signal646is an analog output signal represented by voltage current, or resistance and indicative of the flow rate of the substance traveling through equipment604. In other embodiments, flow signal646is a digital signal indicative of the flow rate of the fluid traveling through equipment604. In further embodiments, the flow signal646is output using a digital communications protocol (e.g. I2C, UART, RS-232, RS-485, Universal Serial Bus, CAN, SPI, etc.).

Turning now toFIG. 7A, a block diagram of another pressure disturbance rejection valve assembly700is shown using a single printed circuit board within one common device chassis, according to some embodiments. Valve assembly700may be used in HVAC system100, waterside system200, airside system300, or BMS400, as described with reference toFIGS. 1-4. Valve assembly700may be identical or substantially similar to valve assembly600as described with reference toFIG. 6A, with the exception that flow sensor processing circuit734(which may be identical or substantially similar to flow sensor processing circuit638) and actuator processing circuit708(which may be identical or substantially similar to actuator processing circuit607) are disposed within printed circuit board706. In some embodiments, printed circuit board706includes communications circuit720. In some embodiments, functionality of flow sensor processing circuit734and actuator processing circuit708are included in a single processing circuit.

Printed circuit board706is further shown to include a power supply circuit740. Power supply circuit740may be an unregulated power supply, a linear regulated power supply, a switching power supply, or a ripple regulated power supply. In some embodiments, power supply circuit740is a wired connection between an exterior power supply and both actuator processing circuit708and flow sensor processing circuit734. Power supply circuit740may be coupled to both actuator processing circuit708and flow sensor processing circuit734through a wired connection. Power supply circuit740may be configured to provide power to a plurality of circuits such as actuator processing circuit708and flow sensor processing circuit734. Power supply circuit740may provide either AC voltage or DC voltage power to both actuator processing circuit708and flow sensor processing circuit734. In some embodiments, power supply circuit740may be a battery that is coupled to both actuator processing circuit708and flow sensor processing circuit734. In short, power supply circuit740may provide power through a chemical reaction that creates a voltage potential.

Referring now toFIG. 7B, an alternative configuration of pressure disturbance rejection valve assembly700ofFIG. 7Awith a single processing circuit762within printed circuit board706is shown, according to some embodiments. As compared toFIG. 7A,FIG. 7Bcan illustrate how printed circuit board706may include a single processing circuit (i.e., processing circuit762) as opposed to multiple processing circuits, thereby simplifying actuator702. In some embodiments, processing circuit762includes some and/or all of the functionality of flow sensor processing circuit734and actuator processing circuit708as described with reference toFIG. 7A. In some embodiments, printed circuit board706includes communications circuit720.

In particular, a processor764of processing circuit762may be similar to and/or the same as both flow sensor processor736and actuator processor710. Further, memory766may be similar to and/or the same as both flow sensor memory738and actuator memory712. In this way, processing circuit762can be configured to generate/determine a flow signal (e.g., similar to and/or the same as flow signal746), provide internal actuator data716to communications circuit720, receive external data718from communications circuit720, generate and provide motor commands732to motor driver inverter724, receive motor current730from motor current sensor722, and/or perform any/all other operations associated with flow sensor processing circuit734and/or actuator processing circuit708. By including functionality of flow sensor processing circuit734and actuator processing circuit708into processing circuit762, actuator702can constructed with fewer components. Simplification of actuator702can result in various benefits such as fewer components in pressure disturbance rejection valve assembly700, streamlined upgrading of components in pressure disturbance rejection valve assembly700, etc.

Turning now toFIG. 8, a block diagram of a pressure disturbance reaction system800is shown, according to some embodiments. Pressure disturbance reaction system800may be used in pressure disturbance rejection valve assembly700with reference toFIG. 7A. For example, pressure disturbance reaction system800is shown to include printed circuit board802, which may be identical or substantially similar to printed circuit board706. However, printed circuit board802may be implemented separate from an actuator. For example, printed circuit board802can be implanted in an environmental controller that regulates environmental conditions in a building (e.g., building10), in a computer of a building operator, in a smart device (e.g., a smart phone), in a cloud computation system, etc. In this way, printed circuit board802can handle control capabilities of an actuator within a single printed circuit board, but can be implemented in other systems that can provide control signals to an actuator.

Turning now toFIG. 9, a flow diagram of a process900for determining and providing a flow signal indicating a flow rate of fluid is shown, according to an exemplary embodiment. In some embodiments, process900may be performed by at least in part by the flow sensor processor640of the flow sensor processing circuit638, described above with reference toFIG. 6A. It should be appreciated that process900is described below as performed by flow sensor processing circuit638and components therein for sake of example. In some embodiments, some and/or all steps of process900can be performed by components of flow sensor processing circuit734as described with reference toFIG. 7A, processing circuit762as described with reference toFIG. 7B, and/or flow sensor processing circuit818as described with reference toFIG. 8.

Process900is shown to commence with step902, in which flow sensor processing circuit638receives raw measurement data set648from transducers634. In some embodiments, raw measurement data set648is received as an analog input signal. Specifically, raw measurement data set648may be received as voltage and/or current signals outputted by transducers634. In general, raw measurement data set648is indicative of measurements gathered by transducers634. However, said measurements may not necessarily be proportionate to a flow rate. Accordingly, further processing of raw measurement data set648may be necessary respective of characteristics of a measured fluid, calibration settings of transducers634, resistances of wires providing raw measurement data set648, etc. In further embodiments, step902is performed by an input/output component of the flow sensor processing circuit638configured to receive the raw measurement data set648and provide it to the flow sensor processor640. At step904, raw measurement data set648is processed and a flow signal646is determined. In some embodiments, step904is performed by flow sensor processing circuit638through a set of instructions stored in flow sensor memory642and executed by flow sensor processor640. The instructions may include calculations in regards to the time of flight of an ultrasonic through the fluid. This may include calculating the difference between an upstream and a downstream signal and generating a flow rate of the fluid based upon the difference. The flow sensor processor640may further provide the input/output component of the circuit with the flow signal646.

In some embodiments, process900concludes with step906, in which the input/output component of the flow sensor processing circuit638provides the flow signal646. In some embodiments, flow signal646is provided as an analog output signal represented by voltage current, or resistance and indicative of the flow rate of the fluid traveling through equipment604. In other embodiments, flow signal646is provided as a digital signal indicative of the flow rate of the fluid traveling through equipment604. In further embodiments, the flow signal646is provided using a digital communications protocol (e.g. I2C, UART, RS-232, RS-485, Universal Serial Bus, CAN, SPI, etc.).

Turning now toFIG. 10, a flow diagram of a process1000for operating a pressure disturbance rejection valve assembly, according to an exemplary embodiment. In some embodiments, process1000may be performed by at least in part by the actuator processor608of actuator processing circuit607, described above with reference toFIG. 6A. It should be appreciated that process1000is described below as performed by actuator processing circuit607and components therein for sake of example. In some embodiments, some and/or all steps of process900can be performed by components of actuator processing circuit708as described with reference toFIG. 7A, processing circuit762as described with reference toFIG. 7B, and/or actuator processing circuit806as described with reference toFIG. 8.

Process1000is shown to commence with step1002, in which actuator processing circuit607receives a flow signal646from flow sensor processing circuit638. In some embodiments, the flow signal646is received as an analog input signal. In other embodiments, the flow signal646is received as a digital input signal indicative of the flow rate of the fluid traveling through equipment604. In further embodiments, the flow signal646is received using a digital communications protocol (e.g. I2C, UART, RS-232, RS-485, Universal Serial Bus, CAN, SPI, etc.). Step1002may be performed by an input/output component of the actuator processing circuit607configured to receive the flow signal646and provide it to the main actuator controller612.

At step1004main actuator controller612can receive a flow rate setpoint. In some embodiments, the flow rate setpoint is provided by an external device, external controller, etc. For example, BMS controller366may determine the flow rate setpoint and provide to the flow rate setpoint to main actuator controller612. In some embodiments, main actuator controller612and/or a different component of actuator602determines the flow rate setpoint based on available data (e.g., the raw measurement data set). At step1006, the main actuator controller612determines an actuator position setpoint. In some embodiments, determination of an actuator position setpoint is determined by a controller employing a PVDC scheme. The actuator position setpoint can be determined such that the flow rate setpoint is achieved. For example, if the flow rate setpoint is higher than a current flow rate, the actuator position setpoint can be determined such that a valve is opened further to increase the flow rate. Process1000concludes with step1008in which the actuator processing circuit607operates the motor626to drive the drive device628and the equipment604to the actuator position setpoint. In further embodiments, process900with reference toFIG. 9and process1000can be performed on a single printed circuit board such as printed circuit board706with reference toFIG. 7A. By performing both processes on printed circuit board706, there are multiple advantages including, for example, less material usage, faster communication, and shared resources such as power supply circuit740.

Referring now toFIG. 11, a graph1100illustrating an example relationship between a flow rate and a voltage measured by a transducer is shown, according to some embodiments. In some embodiments, graph1100is generated by a component of actuator602based on raw measurement data set648as described with reference toFIGS. 6A-6B. For example, graph1100may be generated by raw measurement manipulator658and/or flow rate calculator662of flow signal generator650. In some embodiments, graph1100is provided by a manufacturer of transducers634such that flow rate calculator662can determine the flow rate based on voltage measurements provided by transducers634. In some embodiments, voltage measurements are included in raw measurement data set648as provided by transducers634.

Graph1100is shown to include a series1102. Series1102can illustrate the example relationships between flow rate and voltage. It should be appreciated that the shape of series1102as shown inFIG. 11is purely for sake of example. Series1102can take on any various shape depending on how transducers634measure aspects of a fluid. Series1102can illustrate how voltage increases as flow rate increases. For example, if the voltage is outputted based on a pressure exerted upon a transducer by the fluid, as the pressure increases (i.e., as the flow rate increases), the voltage may increase as well. As such, the exact shape of series1102can be based on how transducers634output data (e.g., as determined based on calibration settings of transducers634). For example, increases in voltage may diminish as the flow rate increases. Advantageously, flow rate calculator662can utilize series1102to determine the flow rate based on voltages indicated by raw measurement data set648. As described above, it should be appreciated thatFIG. 11is given purely for sake of example. Series1102can take on various shapes depending on how transducers634are implemented.

Referring now toFIG. 12, a graph1200illustrating an example relationship between a flow rate and a time of flight of ultrasonic waves is shown, according to some embodiments. Graph1200is shown to include a series1202illustrating the time of flight as a function of the flow rate. In some embodiments, series1202is similar to series1102as described with reference toFIG. 11in that series1202can be utilized to determine the flow rate by flow rate calculator662and may take on various shapes depending on calibrations of transducers634. Graph1200can be provided by a manufacturer, generated based on previously gathered measurements, provided by a user, and/or obtained by another source. In particular, to determine the flow rate, flow rate calculator662can determine a time of flight based on raw measurements of raw measurement data set648and determine a flow rate associated with said time of flight. In this way, valve assembly600can be simplified as all calculations of flow rate are included within actuator602. Utilization of series1202by flow rate calculator662can result in various benefits such as no additional sensors being needed, simplification of transducers634(e.g., transducers634do not need to perform processing), etc. It should be appreciated thatFIG. 12is given purely for sake of example. Series1202can take on various shapes depending on how transducers634are implemented.

Referring now toFIG. 13, a block diagram of a traditional sensor1300for generating a flow proportionate value is shown, according to some embodiments. Sensor1300illustrates the typical complex sensor used in traditional systems. Specifically, sensor1300is shown to include a transducer1302and a converter1304. In some embodiments, transducer1302includes multiple transducers1302.

Sensor1300as illustrated inFIG. 13particularly differs from valve assembly500as described with reference toFIG. 5. In valve assembly500, transducers510are shown to be independent components within conduit512that provide raw measurements directly to actuator502. However, as shown inFIG. 13, transducer1302is a component of sensor1300that provides raw measurements to converter1304. Converter1304illustrates processing components that are inherent to sensors of traditional systems. Specifically, converter1304can be configured to generate a flow proportionate value based on the raw measurements. The raw measurements gathered by transducer1302may not be directly indicative of flow rate. As such, converter1304may include processing components to analyze the raw measurements, adjust the raw measurements based on calibration settings, adjust the raw measurements based on characteristics of a fluid measured by transducer1302, etc.

As an example, if sensor1300is a pressure sensor, transducer1302may output voltage and/or current signals indicative of a pressure exerted on transducer1302. These voltage and/or current signals, however, may not be useful alone as said signals do not account for a density of a fluid measured by transducer1302, calibration settings of transducer1302, etc. In other words, the voltage and/or current signals likely not proportionate to a flow rate of the fluid. As such, based on the raw measurements, converter1304can convert the raw measurements into a flow proportionate value indicative of pressure that is proportional to the flow rate. The pressure value can then be provided to an actuator1306. In this sense, actuator1306is receiving a pre-processed value (i.e., the pressure value) as opposed to actuator502ofFIG. 5which is shown to directly receive raw measurements. An example of a relationship utilized by converter1304are described in detail below with reference toFIG. 14.

Requiring converter1304in sensor1300increases overall costs and complexity associated with a valve assembly as both sensor1300and an actuator1306may require processing components. This can result in more difficult maintenance for the valve assembly as multiple components perform processing and therefore more components may be prone to errors. As such, direct utilization of raw measurements as shown in valve assembly500may provide a variety of benefits over traditional systems.

Referring now toFIG. 14, a graph1400illustrating a relationship between voltage and flow rate generated by a traditional sensor is shown, according to some embodiments. More particularly, graph1400can illustrate how a voltage output of sensor1300(i.e., a flow proportionate value) as described with reference toFIG. 13can be directly correlated to a flow rate. In other words, actuator1306can reference graph1400to determine a flow rate directly based on an output of sensor1300.

Graph1400is shown to include a line1402. Line1402can illustrate how a specific voltage outputted by sensor1300can be immediately correlated with a flow rate without additional processing. This differs from an output of transducers which may take on a variety of values and may require knowledge of fluid-specific properties (e.g., density, specific gravity, etc.) in order to convert the transducer output into a flow rate. Line1402can be utilized by an actuator to determine the flow rate directly based on an outputted voltage of sensor1300without any additional processing. In other words, the relationship illustrated by line1402may be established by processing components of sensor1300by accounting for fluid properties (e.g., density), transducer configurations, etc. and then utilized by the actuator to interpret an output of sensor1300. Therefore, based on raw measurements provided by transducers, the processing components of sensor1300can output a voltage indicative of the flow proportionate value such that the actuator can have implicit knowledge of the flow rate based on the output voltage without requiring the actuator to have knowledge of fluid-specific properties such as density, specific gravity, etc.

Line1402is shown to be limited by a maximum voltage1404. Maximum voltage1404can indicate a largest possible voltage value that can be outputted by sensor1300. Maximum voltage1404is shown to be associated with a maximum flow1406which indicates a largest possible flow value that can be measured for a particular fluid. Maximum voltage1404and/or maximum flow1406can be determined based on calibration settings of the transducers and of sensor1300. If, for example, the transducers are pressure transducers, sensor1300may determine a maximum pressure that the transducers can reasonably measure (e.g., based on provided specifications). Based on the maximum pressure, sensor1300can determine maximum flow1406respective of fluid characteristics, transducer configurations, etc. Maximum voltage1404can be determined as a maximum voltage that can be outputted by sensor1300. In this way, a relationship (i.e., line1402) can be established between maximum flow1406and maximum voltage1404such that an output of sensor1300can be directly indicative of a flow rate.

Referring now toFIG. 15, a graph1500illustrating various relationships between voltage and flow rate associated with transducer outputs is shown, according to some embodiments. As compared to graph1400as described with reference toFIG. 14, graph1500clarifies how the actuators, processing circuits, methods, etc. described throughoutFIGS. 5-10can directly leverage raw measurements outputted by transducers and do not require any pre-processing to be performed by a sensor and/or any other external processing components on the raw measurements.

Graph1500is shown to include a line1502, a line1504, and a line1506. Lines1502-1506can illustrate that transducer outputs may adhere to a variety of relationships depending on fluid properties, transducer calibration, etc. When received by an actuator, transducer outputs may follow any of lines1502-1506and/or any other of a variety of relationships. Accordingly, the actuator may be required to perform processing on the raw measurements to determine how the raw measurements correlate to flow rate. Specifically, it may be the responsibility of the actuator to determine which of lines1502-1506(if any) describe a correlation between transducer outputs and flow rate. It should be noted that lines1502-1506are given purely for sake of example and are not meant to be limiting to relationships that may exist between transducer outputs and flow rate. For example, in an ultrasonic flow sensing system, the flow rate may be calculated based on time of flight of an ultrasonic signal emitted by an ultrasonic transducer, which is a flow disproportionate value.

A notable difference between the flow proportionate values shown in graph1400and the raw transducer output (i.e., flow disproportionate values) shown in graph1500is that each of the flow proportionate values always corresponds to the same flow rate value, regardless of the intensive properties of the fluid being measured. For example, a controller receiving a voltage value of Vmaxas an output from sensor1300can determine that the fluid has a flow rate of Flowmaxusing a fixed relationship between voltage and flow rate that does not depend on fluid density, viscosity, specific gravity, or any other intensive properties of the fluid being measured. Conversely, a controller receiving a raw measurement from a transducer (i.e., a flow disproportionate value) may require knowledge of fluid-specific properties such as density, specific gravity, etc. in order to convert the raw measurement into a flow value. The different lines1502-1506shown in graph1500show how the relationship between voltage and flow rate can differ depending on the fluid-specific properties. Accordingly, a controller receiving a raw measurement from a transducer may require knowledge of such fluid-specific properties in order to know which of the relationships defined by lines1502-1506to use to convert the raw measurement into a flow rate. But a controller receiving a flow proportionate value can use a single stored relationship (e.g., line1402) to convert the flow proportionate value into a flow rate without requiring knowledge of any fluid-specific properties.

Configuration of Exemplary Embodiments