Patent application title:

CLOUD-CONNECTED CONTROLLER FOR HEATING, VENTILATION, AND AIR CONDITIONING EQUIPMENT AND SYSTEMS

Publication number:

US20260185727A1

Publication date:
Application number:

19/005,775

Filed date:

2024-12-30

Smart Summary: A device connects to the Internet and helps manage heating, ventilation, and air conditioning (HVAC) systems. It has a user interface for people to interact with it, either directly or from a distance. The controller collects real-time data about the HVAC system and adjusts it based on user commands and the data it gathers. It can also check for problems in the HVAC system and alert users about its status online. This makes it easier to control and monitor HVAC systems from anywhere. 🚀 TL;DR

Abstract:

One embodiment provides a device comprising a network communications unit configured to connect the device to the Internet, a user interface, and a controller system. The controller system is configured to collect real-time data relating to a heating, ventilation, and air conditioning (HVAC) system that is coupled to the device, receive user input provided at least one of locally via the user interface or remotely via the Internet, and dynamically control the HVAC system based on the real-time data and the user input. The controller system is further configured to monitor for one or more alarm conditions relating to the HVAC system, and provide a remote user with information relating to a status of the HVAC system via the Internet.

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Classification:

F24F11/58 »  CPC main

Control or safety arrangements characterised by user interfaces or communication; Remote control using Internet communication

F24F11/32 »  CPC further

Control or safety arrangements for purposes related to the operation of the system, e.g. for safety or monitoring Responding to malfunctions or emergencies

F24F11/63 »  CPC further

Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values Electronic processing

F24F2140/20 »  CPC further

Control inputs relating to system states Heat-exchange fluid temperature

Description

TECHNICAL FIELD

One or more embodiments relate generally to controllers, and in particular, a cloud-connected controller for heating, ventilation, and air conditioning equipment and systems.

BACKGROUND

Heating, ventilation, and air conditioning (HVAC) is the use of various technologies to control the temperature, humidity, and purity of the air in an enclosed space. HVAC is an important part of residential structures such as single family homes, apartment buildings, hotels, and senior living facilities; medium to large industrial and office buildings such as skyscrapers and hospitals; vehicles such as cars, trains, airplanes, ships and submarines; and in marine environments.

SUMMARY

One embodiment provides a device comprising a network communications unit configured to connect the device to the Internet, a user interface, and a controller system. The controller system is configured to collect real-time data relating to a heating, ventilation, and air conditioning (HVAC) system that is coupled to the device, receive user input provided at least one of locally via the user interface or remotely via the Internet, and dynamically control the HVAC system based on the real-time data and the user input. The controller system is further configured to monitor for one or more alarm conditions relating to the HVAC system, and provide a remote user with information relating to a status of the HVAC system via the Internet.

Another embodiment provides a controller system comprising a network communications unit configured to connect the controller system to the Internet. The controller system further comprises a user interface, at least one processor, and a non-transitory processor-readable memory device storing instructions that when executed by the at least one processor causes the at least one processor to perform operations. The operations include collecting real-time data relating to an HVAC system that is coupled to the controller system, receiving user input provided at least one of locally via a user interface or remotely via the Internet, dynamically controlling the HVAC system based on the real-time data and the user input, monitoring for one or more alarm conditions relating to the HVAC system, and providing a remote user with information relating to a status of the HVAC system via the Internet.

One embodiment provides a method comprising collecting real-time data relating to an HVAC system, receiving user input provided at least one of locally via a user interface or remotely via the Internet, dynamically controlling the HVAC system based on the real-time data and the user input, monitoring for one or more alarm conditions relating to the HVAC system, and providing a remote user with information relating to a status of the HVAC system via the Internet.

These and other features, aspects and advantages of the present invention will become understood with reference to the following description, appended claims and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is an example computing architecture for a cloud-connected controller, in one or more embodiments;

FIG. 2 illustrates an example client-side controller system, in one or more embodiments;

FIG. 3 illustrates an example server-side controller system, in one or more embodiments;

FIG. 4 illustrates an example master-slave configuration including multiple controller devices, in one or more embodiments;

FIG. 5A illustrates a perspective view of an exterior of the controller device, in one or more embodiments;

FIG. 5B illustrates a perspective view of an interior of the controller device, in one or more embodiments;

FIG. 5C is a schematic of an example 24V DC power/control circuit for the controller device, in one or more embodiments;

FIG. 5D is a schematic of an example programmable logic controller (PLC) input/output (I/O) circuit for the controller device, in one or more embodiments;

FIG. 5E is a schematic of an example expansion unit for the controller device, in one or more embodiments;

FIG. 5F is a schematic of example dry contacts for the controller device, in one or more embodiments:

FIG. 5G is a schematic of an example exterior layout of the controller device, in one or more embodiments;

FIG. 5H is a schematic of an example interior layout of the controller device, in one or more embodiments;

FIG. 5I is a schematic of an example network topology of the controller device, in one or more embodiments.

FIG. 6A illustrates a perspective view of an exterior of the controller device, in one or more embodiments;

FIG. 6B illustrates a perspective view of an interior of the controller device, in one or more embodiments;

FIG. 6C is a schematic of an example 120/208V AC power circuit for the controller device, in one or more embodiments;

FIG. 6D is a schematic of an example 120/208V AC power circuit and an example 24V DC power circuit for the controller device, in one or more embodiments;

FIG. 6E is a schematic of an example 24V DC power/control circuit for the controller device, in one or more embodiments;

FIG. 6F is a schematic of an example PLC I/O circuit for the controller device, in one or more embodiments;

FIG. 6G is a schematic of an example expansion unit for the controller device, in one or more embodiments;

FIG. 6H is a schematic of example dry contacts for the controller device, in one or more embodiments;

FIG. 6I is a schematic of an example exterior layout of the controller device, in one or more embodiments;

FIG. 6J is a schematic of an example interior layout of the controller device, in one or more embodiments;

FIG. 6K is a schematic of an example network topology of the controller device, in one or more embodiments;

FIG. 6L illustrates an example exterior user interface positioned at a front of the controller device, in one or more embodiments;

FIG. 6M illustrates an example interior user interface positioned inside the controller device, in one or more embodiments;

FIG. 7 is a flowchart of an example process for implementing a cloud-connected controller for a HVAC system, in one or more embodiments; and

FIG. 8 is a high-level block diagram showing an information processing system comprising a computer system useful for implementing the disclosed embodiments.

The detailed description explains the preferred embodiments of the invention together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION

One or more embodiments relate generally to controllers, and in particular, a cloud-connected controller for heating, ventilation, and air conditioning equipment and systems. One or more embodiments relate generally to networking platforms, and in particular, a method and system for artificial intelligence (AI)-powered professional networking with enhanced in-person event driven matching. One embodiment provides a device comprising a network communications unit configured to connect the device to the Internet, a user interface, and a controller system. The controller system is configured to collect real-time data relating to a heating, ventilation, and air conditioning (HVAC) system that is coupled to the device, receive user input provided at least one of locally via the user interface or remotely via the Internet, and dynamically control the HVAC system based on the real-time data and the user input. The controller system is further configured to monitor for one or more alarm conditions relating to the HVAC system, and provide a remote user with information relating to a status of the HVAC system via the Internet.

Another embodiment provides a controller system comprising a network communications unit configured to connect the controller system to the Internet. The controller system further comprises a user interface, at least one processor, and a non-transitory processor-readable memory device storing instructions that when executed by the at least one processor causes the at least one processor to perform operations. The operations include collecting real-time data relating to an HVAC system that is coupled to the controller system, receiving user input provided at least one of locally via a user interface or remotely via the Internet, dynamically controlling the HVAC system based on the real-time data and the user input, monitoring for one or more alarm conditions relating to the HVAC system, and providing a remote user with information relating to a status of the HVAC system via the Internet.

One embodiment provides a method comprising collecting real-time data relating to an HVAC system, receiving user input provided at least one of locally via a user interface or remotely via the Internet, dynamically controlling the HVAC system based on the real-time data and the user input, monitoring for one or more alarm conditions relating to the HVAC system, and providing a remote user with information relating to a status of the HVAC system via the Internet.

FIG. 1 is an example computing architecture 100 for a cloud-connected controller, in one or more embodiments. The computing architecture 100 comprises at least one controller device 110 (i.e., the cloud-connected controller). The controller device 110 includes resources, such as one or more processor units 111 and one or more storage units 112. One or more applications may execute/operate on the controller device 110 utilizing the resources of the controller device 110.

In one embodiment, the one or more applications on the controller device 110 include a client-side controller system 120 for controlling a HVAC system 160 including one or more HVAC units 161. Each HVAC unit 161 is an HVAC equipment, part, or accessory such as, but not limited to, a heat pump, an air conditioner, a boiler, a chiller, a dehumidifier, a humidifier, a radiant system, a furnace, a heater, a thermostat, a storage tank, an air filter, an air purifier, a fan, a cooler, etc. The controller device 110 is integrated in or coupled to the HVAC system 160. For example, in one embodiment, the controller device 110 is installed within proximity of the HVAC system 160.

For example, in one embodiment, a HVAC system 160 comprises a heat pump water heater system including HVAC units 161 such as, but not limited to, one or more heat pumps, one or more storage tanks, one or more swing tanks, one or more expansion tanks, one or more thermostats, etc. The controller device 110 is mounted to a solid frame or wall, and installed within proximity of the heat pumps and/or tanks to reduce or minimize wire run lengths.

In one embodiment, the controller device 110 comprises one or more input/output (I/O) units 113 integrated in or coupled to the controller device 110. In one embodiment, the one or more I/O units 113 include, but are not limited to, a local physical user interface (PUI) and/or a graphical user interface (GUI), such as a remote control, a keyboard, a keypad, a touch interface, a programmable logic controller (PLC) user interface, a touch screen, a knob, a button, a display screen, etc. In one embodiment, a user 10 can utilize at least one I/O unit 113 (e.g., a PUI or GUI) to configure one or more configuration settings, provide user input (e.g., user preferences, user feedback), etc.

Examples of a user 10 include, but is not limited to, a HVAC service representative (e.g., a professional HVAC installation, repair, and maintenance technician), an engineer, a home owner, a tenant, a maintenance manager, etc.

In one embodiment, the controller device 110 comprises one or more sensor units 114 integrated in or coupled to the controller device 110, such as, but not limited to, a temperature sensor, a camera, a microphone, a GPS, a motion sensor, etc.

In one embodiment, the controller device 110 comprises a communications unit (i.e., network communications unit) 115 configured to exchange data with a remote computing environment 130 and/or an electronic device 170 (e.g., utilized by a user 10), over a communications network/connection 150 (e.g., a wireless connection such as a Bluetooth® connection, a Wi-Fi connection, or a cellular data connection; a wired connection; or a combination of both a wireless connection and a wired connection). The communications unit 115 may comprise any suitable communications circuitry operative to connect to a communications network and to exchange communications operations and media between the controller device 110 and other devices connected to the same communications network 150. The communications unit 115 may be operative to interface with a communications network using any suitable communications protocol such as, for example, Wi-Fi (e.g., an IEEE 802.11 protocol), Bluetooth®, high frequency systems (e.g., 900 MHz, 2.4 GHz, and 5.6 GHz communication systems), infrared, GSM, GSM plus EDGE, CDMA, quadband, and other cellular protocols, VOIP, TCP-IP, or any other suitable protocol.

In one embodiment, the communications unit 115 includes a network router such as, but not limited to, a network router with an LTE SIM card.

Examples of an electronic device 170 include, but is not limited to, a mobile electronic device (e.g., an optimal frame rate tablet, a smart phone, a laptop, etc.), a wearable device (e.g., a smart watch, a smart band, a head-mounted display, smart glasses, etc.), a desktop computer, a gaming console, an Internet of things (IoT) device, etc.

In one embodiment, an electronic device 170 includes one or more applications loaded onto or downloaded to the electronic device 170, such as a camera application, a social media application, a web browser, etc. For example, in one embodiment, the one or more applications on the electronic device 170 include a software mobile application 171 configured to interface and exchange data with the controller system 120 (e.g., over a wireless connection such as a Bluetooth® connection, a Wi-Fi connection, or a cellular data connection). A user 10 can remotely configure and control the controller device 110 and/or the one or more HVAC units 161 via the application 171. As another example, in one embodiment, a user 10 can remotely configure and control the controller device 110 and/or the one or more HVAC units 161 by accessing the controller system 140 via a web browser on the electronic device 170.

In one embodiment, the remote computing environment 130 includes resources, such as one or more servers 131 and one or more storage units 132. One or more applications that provide higher-level services may execute/operate on the remote computing environment 130 utilizing the resources of the remote computing environment 130. In one embodiment, the one or more applications on the remote computing environment 130 include a server-side AI-powered controller system 140 configured to remotely configure and control one or more controller devices 110. As described in detail later herein, the client-side controller system 120 is configured to interface and exchange data with the AI-powered controller system 140.

In one embodiment, the remote computing environment 130 provides an online platform for hosting one or more online services (e.g., the server-side controller system 140, etc.) and/or distributing one or more applications, application updates, and/or AI machine learning models. For example, the client-side controller system 120 may be loaded onto or downloaded to the controller device 110 from the remote computing environment 130 that maintains and distributes updates for the system 120, including AI machine learning models. As another example, the application 171 may be loaded onto or downloaded to the electronic device 170 from the remote computing environment 130 that maintains and distributes updates for the application 171. In another embodiment, the application 171 may be downloaded to the electronic device 170 from an application marketplace (e.g., App Store®, Play Store®, etc.) executing/operating on a different remote cloud computing environment.

In one embodiment, the remote computing environment 130 may comprise a cloud computing environment providing shared pools of configurable computing system resources and higher-level services (e.g., data analytics). The client-side controller system 120 is configured to interface and exchange data with the AI-powered controller system 140 in the cloud. In another embodiment, the remote computing environment 130 may comprise an edge computing environment providing more safe, scalable, and reliable data processing and computation.

The systems 120, 140 provide a user 10 with multiple features/functionalities, as described herein below.

In one embodiment, the controller device 110 is a standalone device, independent of existing HVAC equipment, parts, and accessories. In another embodiment, the controller device 110 is integrated into, or implemented as part of, existing HVAC equipment, parts, and accessories. For example, the controller device 110 can be integrated into, or implemented as part of, a power distribution and control panel for a heat pump water heater system.

In one embodiment, a controller device 110 is configured to control multiple HVAC systems 160. For example, in one embodiment, a controller device 110 is configured to control a primary HVAC system 160 and one or more backup/redundant HVAC systems 160. As another example, in one embodiment, a controller device 110 is designated as a master controller in a master-slave configuration to control multiple HVAC systems 160, as described in detail herein below.

FIG. 2 illustrates an example client-side controller system 200, in one or more embodiments. In one embodiment, the system 200 is integrated into, or implemented as part of, a client-side controller system 120 (FIG. 1) of a controller device 110 (FIG. 1) for an HVAC system 160.

In one embodiment, the client-side controller system 200 comprises a data collection and monitoring unit 210 configured to collect and monitor real-time data relating to an HVAC system 160. For example, the data collection and monitoring unit 210 is configured to collect and monitor real-time consumption/usage data and/or sensor data. Examples of usage/consumption data include, but is not limited to, energy consumption, water consumption, power consumption, etc. Examples of sensor data include, but is not limited to, temperature data captured/measured by one or more temperature sensors integrated in or coupled to the HVAC system 160.

Examples of a temperature sensor include, but is not limited to, a NTC (negative temperature coefficient) thermistor.

In one embodiment, the client-side controller system 200 comprises an on-device operation unit 220 configured to locally control the HVAC system 160 based on consumption/usage data, sensor data, one or more schedules, user preferences, and/or user feedback for the HVAC system 160. The on-device operation unit 220 is further configured to detect one or more abnormalities/irregularities (e.g., a leak) with the HVAC system 160 based on consumption/usage data and/or sensor data.

In one embodiment, the client-side controller system 200 comprises a user interface unit 230 configured to receive user input (e.g., via an end-user application 171, via a virtual dashboard accessed via a web browser, or via one or more I/O units 113, such as a PUI or a GUI) and, based on the user input, turn on/off the HVAC system 160 or configure one or more configuration settings of the controller device 110, one or more operating parameters of the HVAC system 160, one or more schedules for the HVAC system 160, and/or one or more other operational aspects of the HVAC system 160. The user input may include user preferences and/or user feedback. Therefore, the user interface unit 230 allows a user 10 (e.g., an engineer) to remotely control the HVAC system 160 to adjust/fine-tune the operation of the HVAC system 160 (e.g., change configuration settings, change schedules, turn on/off, adjust/fine-tune machine learning models 280, etc.).

In one embodiment, the user interface unit 230 is configured to provide a user 10 with information relating to the HVAC system 160 such as, but not limited to, historical and/or real-time consumption/usage data, sensor data, schedules, configuration settings, operating parameters, alerts and notifications (e.g., detected abnormalities/irregularities), user preferences, user feedback, etc. For example, the user interface unit 230 generates one or more user interfaces (e.g., GUIs) including the information for display within an end-user application 171, within a virtual dashboard accessed via a web browser, and/or via one or more I/O units 113 of the controller device 110, such as a display screen (e.g., user interface 622 in FIG. 6J). The user interface unit 230 allows a user 10 (e.g., an engineer) to access, view, and/or update information (e.g., user preferences) relating to the HVAC system 160.

In one embodiment, the client-side controller system 200 comprises a notifications unit 240 configured to receive and send alerts and notifications for (or relevant to) the HVAC system 160. The notifications unit 240 is configured to receive alerts and notifications from a user 10 via an end-user application 171, a virtual dashboard the user 10 accessed via a web browser, an I/O unit 113 (e.g., a PUI or GUI, such as a PLC 509 in FIG. 5H, a user interface 622 in FIGS. 61 and 6L, or a PLC 617 in FIGS. 6J and 6M) of the controller device 110 for the HVAC system 160, and/or the server-side controller system 140. The notifications unit 240 is also configured to receive alerts and notifications (e.g., planned or potential blackout/brownout, wildfire alert, weather alert, earthquake alert, etc.) broadcast/sent by a third-party such as, but not limited to, a utility provider, a national or municipal agency (e.g., National Weather Service®), etc.

The notifications unit 240 is configured to send alerts and notifications for (or relevant to) the HVAC system 160 via an end-user application 171, a virtual dashboard for the HVAC system 160, an I/O unit 113 (e.g., a display screen, an alarm or light indicator, a speaker, etc.) of the controller device 110 for the HVAC system 160, and/or other means of electronic communication such as, but not limited to, email, text messaging (e.g., SMS), etc. For example, if a leak is detected (e.g., via the on-device operation unit 220), the notifications unit 240 can send a notification of the leak. As another example, the notifications unit 240 can send maintenance reminders periodically (e.g., based on a frequency specified by user preferences). As another example, if energy consumption/usage is high or if an alert of a planned or potential blackout/brownout was broadcast/sent by a utility provider, the notifications unit 240 can send an alert to a user 10 requesting the user 10 conserve energy. As another example, in one embodiment, if the notifications unit 240 receives a wildfire alert or another type of emergency/public safety alert relevant to a particular geographical location the HVAC system 160 is located at or within proximity of, the notifications unit 240 can notify a user 10 of the need to temporarily turn off the HVAC system 160 for safety reasons.

In one embodiment, the client-side controller system 200 comprises a load shifting unit 250 for implementing load shifting in the HVAC system 160. Specifically, the load shifting unit 250 is configured to manage load demand (e.g., power demand, water demand, energy demand, etc.) on the HVAC system 160 by shifting the load demand from peak hours to off-peak hours (i.e., shifting consumption/usage to a different period of time while maintaining constant total consumption/usage). In one embodiment, the load shifting unit 250 is configured to interface and exchange data with a load shifting application operated by a utility provider. For example, in one embodiment, the controller device 110 includes an Ecoport On/Off sensor (or another sensor compliant with CTA-2045 standard) for detecting a load shift signal from a utility provider.

In one embodiment, the client-side controller system 200 comprises a master/slave unit 260 for implementing a master-slave architecture in which the controller device 110 is configured as a master (“master controller”) or a slave (“sub-controller”). Specifically, a first controller device 110 can be connected to one or more other controller devices 110 (corresponding to one or more other HVAC systems 160 located at or within proximity of the HVAC system 160). Of the controller devices 110, only one is designated as a master controller (e.g., the first controller device 110), while each remaining controller device 110 is designated as a sub-controller. This results in a configuration in which multiple controller devices 110 are connected together to operate multiple HVAC systems 160 together via the master controller.

In one embodiment, the client-side controller system 200 comprises a price optimization unit 270 for implementing price optimization in the HVAC system 160. Specifically, the price optimization unit 270 is configured to obtain dynamic price rates for energy, and dynamically adjust, based on the rates obtained, energy consumption/usage of the HVAC system 160, thereby reducing the consumption/usage at peak hours during which the price rates are high. In one embodiment, a utility company broadcasts dynamic price rates which are captured by either the client-side controller system 200 or the server-side controller system 140. By factoring into account dynamic price rates instead of static price rates, the controller device 110 dynamically adapts to real-time price changes/shifts. In one embodiment, the controller system 200 implements price optimization in lieu of load shifting.

In one embodiment, one or more components of the client-side controller system 200 (e.g., the on-device operation unit 220, the load shifting unit 250, the price optimization unit 270, etc.) utilizes one or more AI machine learning models 280. In one embodiment, the machine learning models 280 include at least one machine learning model 280 customized/personalized for the HVAC system 160 based on consumption/usage data, sensor data, and/or user input (e.g., user preferences, user feedback) for the HVAC system 160 and/or one or more other HVAC systems 160 in similar contexts (e.g., similar households, similar geographical locations, similar consumption/usage patterns, etc.).

FIG. 3 illustrates an example server-side controller system 300, in one or more embodiments. In one embodiment, the system 300 is integrated into, or implemented as part of, the server-side controller system 140 in FIG. 1.

In one embodiment, the server-side controller system 300 comprises a data collection unit 310 configured to collect data relating to one or more remote HVAC systems 160. For example, in one embodiment, the data collection unit 310 collects consumption/usage data, sensor data, and user input (e.g., user preferences, user feedback) for a remote HVAC system 160 from a controller device/master controller device 110 for the HVAC system 160.

In one embodiment, each controller system 200/300 implements one or more data protection measures (or one or more data privacy and security protocols) to ensure the confidentiality and protection of private data, as well as comply with industry standards and regulations and/or global data privacy and security regulations. For example, in one embodiment, each controller system 200/300 utilizes one or more advanced/robust data encryption protocols, and/or one or more secure data transmission channels to ensure data privacy and confidentiality. As another example, in one embodiment, each controller system 200/300 implements one or more user permission protocols in which the controller system 200/300 obtains and manages user consent from a user 10 for collection of data relating to a HVAC system 160. As yet another example, in one embodiment, each controller system 200/300 safeguards private data utilizing secure data storage and one or more advanced/robust authentication protocols to protect private data integrity.

In one embodiment, the server-side controller system 300 comprises an off-device operation unit 320 configured to remotely configure and control one or more controller devices 110 and one or more HVAC systems 160 corresponding to the one or more controller devices 100. For example, in one embodiment, the off-device operation unit 320 exchanges data (e.g., instructions, commands) with an on-device operation unit 220 of a controller device/master controller device 110 for a remote HVAC system 160, such that the off-device operation unit 320 can trigger the on-device operation unit 220 to turn on/off the HVAC system 160 or configure one or more configuration settings of the controller device 110, one or more operating parameters of the HVAC system 160, one or more schedules for the HVAC system 160, and/or one or more other operational aspects of the HVAC system 160. In one embodiment, the off-device operation unit 320 triggers the on-device operation unit 220 based on user input (e.g., user preferences, user feedback, etc.) and/or consumption/usage data and/or sensor data relating to the remote HVAC system 160. The off-device operation unit 320 allows a user 10 (e.g., an engineer) to remotely configure and control a controller device 110 and an HVAC system 160 corresponding to the controller device 110 via the cloud (i.e., provides remote connectivity).

In one embodiment, the server-side controller system 300 comprises a user interface unit 330 configured to generate one or more virtual dashboards for one or more remote HVAC systems 160. A virtual dashboard for a remote HVAC system 160 comprises one or more GUIs that include information relating to the HVAC system 160 such as, but not limited to, historical and/or real-time consumption/usage data, sensor data, schedules, configuration settings, operating parameters, alerts and notifications (e.g., detected abnormalities/irregularities), user preferences, user feedback, etc. In one embodiment, a user 10 can access and view a virtual dashboard for a remote HVAC system 160 via an end-user application 171 or a web browser. The user interface unit 330 allows a user 10 (e.g., an engineer) to remotely access, view, and/or update information (e.g., user preferences) relating to a controller device 110 and a HVAC system 160 corresponding to the controller device 110 via the cloud (i.e., provides remote connectivity and a cloud interface). In one embodiment, a user 10 may require an active subscription in order to access the remote connectivity and cloud interface features. For example, as part of an active subscription, an engineer or HVAC technician can remotely monitor and adjust/fine-tune a HVAC system 160 owned by a home owner who is a paying subscriber, and the home owner can remotely access, view, and/or update information (e.g., user preferences) relating to the HVAC system 160 and its controller device 110 via the cloud interface.

In one embodiment, the server-side controller system 300 comprises a notifications unit 340 configured to receive and send alerts and notifications for (or relevant to) one or more remote HVAC systems 160. The notifications unit 340 is configured to receive alerts and notifications for a HVAC system 160 from a user 10 via an end-user application 171, a virtual dashboard the user 10 accessed via a web browser, and/or an I/O unit 113 (e.g., a PUI or GUI, such as a PLC 509 in FIG. 5H, a user interface 622 in FIGS. 6I and 6L, or a PLC 617 in FIGS. 6J and 6M) of a controller device 110 for the HVAC system 160. The notifications unit 340 is configured to receive alerts and notifications (e.g., planned or potential blackout/brownout, wildfire alert, weather alert, earthquake alert, etc.) broadcast by a third-party such as, but not limited to, a utility company, a national or municipal agency (e.g., National Weather Service®), etc.

The notifications unit 340 is configured to send alerts and notifications for (or relevant to) a remote HVAC system 160 via an end-user application 171, a virtual dashboard for the HVAC system 160, an I/O unit 113 (e.g., a display screen, an alarm or light indicator, a speaker, etc.) of a controller device 110 for the HVAC system 160, and/or other means of electronic communication such as, but not limited to, email, text messaging (e.g., SMS), etc. For example, in one embodiment, the notifications unit 340 exchanges data (e.g., instructions, commands) with a notifications unit 240 of a controller device 110 for a remote HVAC system 160, such that the notifications unit 340 can trigger the notifications unit 240 to display or sound an alert or notification via one or more I/O units 113 of the controller device 110. As another example, in one embodiment, if the notifications unit 340 receives a wildfire alert or another type of emergency/public safety alert relevant to a particular geographical location, the notifications unit 340 can propagate the alert to a controller device 110 for a remote HVAC system 160 located at or within proximity of the geographical location.

In one embodiment, the server-side controller system 300 comprises an optional federated learning unit 350 for implementing federated learning. Specifically, the federated learning unit 350 is configured to coordinate the collaborative training of one or more global AI machine learning models 280 across one or more controller devices 110 for one or more remote HVAC systems 160 in similar contexts (e.g., similar households, similar geographical locations, similar consumption/usage patterns, etc.). For example, an initial global AI machine learning model is deployed to a group of controller devices 110 for HVAC systems 160 in a similar context (e.g., located in the same neighborhood). Each controller device 110 of the group locally trains the initial global AI machine learning model based on consumption/usage data for a HVAC system 160 it controls, local sensor data for the HVAC system 160, and/or user input (e.g., user preferences, user feedback) for the HVAC system 160, resulting in a local AI machine learning model that is then shared with the federated learning unit 350. The federated learning unit 350 fine-tunes the global AI machine learning model based on each local AI machine learning model it receives from each controller device 110 of the group. This mitigates the risk of compromising data security or privacy as the controller devices 110 never share private data—such as consumption/usage data, sensor data, and user input—with the federated learning unit 350.

In one embodiment, a user 10 may require an active subscription in order to access the AI machine learning features.

In one embodiment, the server-side controller system 300 comprises a database management unit 360 configured to: (1) maintain one or more optional usage databases 370 including consumption/usage data, sensor data, schedules, configuration settings, operating parameters, alerts and notifications, user preferences, and/or user feedback for one or more remote HVAC systems 160, and (2) maintain one or more optional price rates databases 390 including dynamic and/or static price rates for energy supplied by different utility companies or in different geographical locations. In one embodiment, each database 370, 390 is implemented on at least one storage unit 132 (FIG. 1) of the remote computing environment 130 (FIG. 1).

FIG. 4 illustrates an example master-slave configuration 400 including multiple controller devices 110, in one or more embodiments. In one embodiment, the configuration 400 includes a first controller device 110 (e.g., CONTROLLER DEVICE 1) for a first HVAC system 160 (e.g., HVAC SYSTEM 1) and one or more other controller devices 110 (e.g., CONTROLLER DEVICE 2 and CONTROLLER DEVICE 3) for one or more other HVAC systems 160 (e.g., HVAC SYSTEM 2 and HVAC SYSTEM 3). The first HVAC system 160 and the one or more other HVAC systems 160 are either located at the same geographic location or within proximity of one another (e.g., in the same neighborhood). The first controller device 110 is designated as a master controller, and each other controller device 110 is designated as a sub-controller. The master controller controls the first HVAC system 160, as well as the one or more other HVAC systems 160 (e.g., the master controller sends commands, instructions, etc., to the sub-controllers).

In one embodiment, the multiple controller devices 110 are connected together by chaining the controller devices 110 together via wired connections such as, but not limited to, physical LAN cables. In another embodiment, the multiple controller devices 110 are connected together via wireless connections such as, but not limited to, a WiFi hub connection for use by the controller devices 110 only. This allows the sub-controllers to wirelessly exchange data with the master controller over WiFi, requiring only the master controller to be connected to a network router 116 (e.g., with a LTE SIM card) via a wired connection. In one embodiment, the network router 116 is integrated into, or implemented as part of, the first controller device 110 (e.g., included in its communication unit 115). The configuration 400 saves on costs (e.g., annual subscription costs) as only one controller device 110—the master controller—requires a network router 116 (e.g., with a LTE SIM card).

For example, in one embodiment, controller devices 110 for HVAC systems 160 of houses or buildings located within proximity of one another (e.g., located in the same neighborhood) can be remotely controlled via one of the controller devices 110 designated as a master controller. Each remaining controller device 110 is designated as a sub-controller, and exchanges data with the master controller. Data from the sub-controllers can be propagated/routed to the server-side controller system 140/300 (FIG. 1/FIG. 3) in the cloud via the master controller.

FIGS. 5A-5I illustrate an example controller device 500 for a heat pump water heater (HPWH) system, in one or more embodiments. Specifically, FIG. 5A illustrates a perspective view of an exterior of the controller device 500, in one or more embodiments. FIG. 5B illustrates a perspective view of an interior of the controller device 500, in one or more embodiments. In one embodiment, the controller device 500 is integrated into, or implemented as part of, the controller device 110 in FIG. 1. In one embodiment, the controller device 500 is a standalone device coupled to the HPWH system. The HPWH system comprises at least one storage tank for storing water and at least one heat pump (HP) for heating water from the at least one storage tank.

In one embodiment, the controller device 500 monitors real-time readings from multiple temperature sensors positioned throughout the HPWH system. For example, one or more temperature sensors are positioned into one or more thermowells of the at least one storage tank (“tank sensors”). As another example, a temperature sensor is positioned into a thermowell of a pipe connecting the at least one storage tank to each inlet of each heat pump (“HP inlet sensor”). As another example, a temperature sensor is positioned at a location that will allow the sensor to accurately register outside air (OA) or ambient temperature surrounding the at least one heat pump (“OA sensor”). The OA sensor is shielded from sunlight, and positioned away from warm surfaces and warm exhaust air. As described in detail herein, in one embodiment, the controller device 500 monitors real-time temperatures of the at least one storage tank, an inlet of the at least one heat pump, and the outside air.

FIG. 5C is a schematic of example 24V DC power/control circuit for the controller device 500, in one or more embodiments. In one embodiment, incoming power wires to the controller device 500 are kept separate from signal wires (i.e., control wires) or a singular Modbus cable interconnecting the controller device 500 to the temperature sensors and the heat pumps (i.e., units).

In one embodiment, a circuit breaker is installed, and the incoming power wires that supply power are connected to one or more terminals (e.g., L1, NEU, and GND terminals) of the controller device 500.

FIG. 5D is a schematic of an example PLC I/O for the controller device 500, in one or more embodiments. FIG. 5E is a schematic of an example expansion unit for the controller device 500, in one or more embodiments. FIG. 5F is a schematic of example dry contacts for the controller device 500, in one or more embodiments. In one embodiment, two pairs of signal wires are required between the controller device 500 and each heat pump-one pair for a run signal, and another pair for a unit alarm signal. For example, in one embodiment, signal wires connect a HP Run I/O terminal and an Alarm I/O terminal of the controller device 500 to a Unit Start Input connection and an Error Signal Output connection of a heat pump, respectively. Signal wires from the controller device 500 are interconnected to the heat pumps in accordance with a total number of heat pumps in an array.

In another embodiment, the client/server data communications protocol Modbus is used to facilitate communication between the at least one heat pump and the controller device 500. Specifically, instead of signal wires, a singular Modbus cable connects each heat pump of the HPWH system to a Modbus network for the HPWH system. This allows additional information relating to the at least one heat pump such as, but not limited to, internal temperatures, motor speeds, etc., to be accessed and viewed on the Modbus network, e.g., via an end-user application 171, a virtual dashboard accessed via a web browser, an I/O unit 113 (e.g., a PUI or GUI, such as a PLC 509 in FIG. 5H) of the controller device 500, etc.

In one embodiment, if the HPWH system has more than 5 heat pumps, multiple heat pumps are interconnected to each I/O terminal of the controller device 500.

In one embodiment, the controller device 500 is optionally connected to a Building Management System (BMS) or an alarm indicator. An isolating relay may be required if connecting the controller device 500 to a BMS.

In one embodiment, the controller device 500 includes a General Alarm output relay. The General Alarm output relay is 24V DC wet contact, i.e., the Alarm I/O terminals of the controller device 500 have 24V power applied when a General Alarm is present. The wet contact also allows for a 24V alarm indicator (e.g., an alarm indicator light or an alarm indicator buzzer) to be powered from the Alarm I/O terminals of the controller device 500, such that the alarm indicator is energized whenever a unit alarm signal is present. The General Alarm output relay is N/O in that it closes to signal an alarm condition.

In one embodiment, for a BACnet MS/TP (Master Slave Token Passing) connection between the BMS and the controller device 500, wires from the BMS are wired directly to Tx, RX and GND terminals of a PLC of the controller device 500. In one embodiment, for a BACnet IP connection between the BMS and the controller device 500, an ethernet cable from the BMS is plugged directly into the PLC.

In one embodiment, for each heat pump, a heat pump resistor is installed on the heat pump, and the resistor is connected to one or more terminals of the one or more tank sensors.

In one embodiment, the controller device 500 can be enabled or disabled via its local user interface or a BMS (Building Management System) command. When enabled (i.e., in On operating mode), the controller device 500 will operate under its own internal controls to stage the heat pumps and monitor for alarm conditions. A configuration setting indicative of whether the controller device 500 is enabled or disabled is stored in a memory of the controller device 500, thereby allowing the controller device 500 to automatically restart after a power failure. To prevent the controller device 500 from calling the heat pumps to run (i.e., start heating) after a power cycle, the controller device 500 is disabled (i.e., in Off operating mode) before restarting.

In one embodiment, for each heat pump that is enabled, the controller device 500 calls the heat pump to run by sending a run signal to the heat pump. The heat pump then receives, via its inlet, water from the at least one storage tank.

In one embodiment, the controller device 500 determines whether to call the heat pumps to run by monitoring at least, but not limited to, the following: (1) real-time temperature of water in the at least one storage tank (“tank temperature”) via the one or more tank sensors, and (2) real-time temperature of water at an inlet of at least one heat pump (“HP inlet temperature”) via the HP inlet sensor. As the tank temperature falls, stages of heating (“heating stages”) are called on at corresponding set points. For example, the controller device 500 can control up to 12 heat pumps in 4 heating stages. In one embodiment, each heating stage's set point is set to 113° F. by default. Each heating stage's set point is individually adjustable. A first heating stage (“Stage 1”) must always be set to trigger On first and Off last.

In one embodiment, the controller device 500 includes an Ecoport On/Off sensor (or another sensor compliant with CTA-2045 standard) for detecting a load shift signal from a utility provider, wherein the signal comprises a request to load shift. If the controller device 500 receives a load shift signal, set points for the individual heating stages are adjusted based on a requested load shift.

In one embodiment, for price optimization, the controller device 500 invokes the HPWH system to load up (i.e., increase demand for electricity) during periods of low daily electricity price rates, and further invokes the HPWH system to load shed (i.e., reduce demand for electricity) during periods of high daily electricity price rates. Times for, and frequency of, loading up and load shedding are adjustable based on dynamic price rates provided by a utility provider.

In one embodiment, a number of control stages the controller device 500 implements will equal a number of heat pumps that are enabled (which is specified in the configuration settings for the controller device 500).

In one embodiment, the controller device 500 will delay, for a pre-determined amount of time (e.g., about 5 seconds), a call to the heat pumps to run to ensure that the tank temperature remains steady under a corresponding set point. If multiple control stages are triggered within a short time frame, the controller device 500 will stagger start times of the heat pumps that are enabled in short intervals (e.g., 15 second intervals) to minimize or reduce the HPWH system's peak current draw. Upon receiving a call to run from the controller device 500, each heat pump that is enabled will delay its start for a pre-determined amount of time (e.g., 4 minutes) before its compressor is energized. A heating cycle will end if the HP inlet temperature increases to a corresponding set point.

In one embodiment, for a heat pump that is enabled, the controller device 500 utilizes the following anti-short cycle safety timers for the heat pump to prevent an undesired set point (e.g., 122° F.): Min (minimum) On time, Min Off time, and Min Consecutive Start time (i.e., time between two starts). When the heat pump is enabled, its Min On time and Min Consecutive Start time safety timers begin to count down. The heat pump will remain on until the counter of the Min On time safety timer has expired, and the heat pump will not run again until the counter of the Min Consecutive Start time safety timer has expired. When the controller device 500 stages the heat pump off, its Min Off time safety timer begins to count down. The controller device 500 will not attempt to restart the heat pump until the counters of both its Min Off time and Min Consecutive Start time safety timers have expired.

In one embodiment, the controller device 500 maintains balanced run times by alternating unit (i.e., heat pump) starts. For example, the controller device 500 balances the run times of heat pumps that are enabled by starting the heat pumps in order of lowest operating hours. If a heat pump is replaced, one or more corresponding run hour counters that the controller device 500 utilizes for the heat pump can be individually reset.

In one embodiment, the controller device 500 is configured to monitor real-time outdoor air (OA) temperature via the OA sensor, and automatically activate/execute freeze protection mode/cycles when the OA temperature drops below an adjustable threshold (e.g., below 20° F.), i.e., in extreme conditions.

In the freeze protection mode/cycles, the controller device 500 will run all heat pumps in adjustable ON/OFF cycles. The short cycle safety timers for the heat pumps will remain in effect to protect the heat pumps. In one embodiment, the controller device 500 pauses its run signal to the heat pumps if the HP inlet temperature is equal to or higher than an OFF set point for Stage 1; the run signal will resume when the HP inlet temperature drops below the OFF set point for Stage 1. If the tank temperature and the HP inlet temperature is low enough to trigger the first heating stage, the controller device 500 will call, via a run signal, all heat pumps to run. The run signal will continue until the HP inlet temperature rises to the OFF set point for Stage 1.

In one embodiment, each unit (i.e., heat pump) of the HPWH system can be operated in Manual, Auto, or Off modes by accessing a service menu via the controller device's local user interface.

If a unit (i.e., heat pump) of the HPWH system experiences a critical fault, the unit will report this by sending a unit alarm signal to an I/O terminal (e.g., Alarm I/O terminal) of the controller device 500 via the unit's alarm contact closure with the controller device 500. Upon receiving the unit alarm signal, the controller device 500 will close its General Alarm output relay. The General Alarm output relay remains closed as long as the unit alarm signal is active. When the unit alarm signal clears, the controller device 500 will open the General Alarm output relay and, if the unit was shut off, place the unit back into a queue to be called to run when required.

For example, if the unit alarm signal is from a heat pump, the controller device 500 can be configured to either: (1) continue to run the heat pump (this is typically the case if multiple units are connected to each I/O terminal of the controller device 500), or (2) stop the run signal to the heat pump, and call another heat pump next in the queue to run (this is typically the case if only one unit is connected to each I/O terminal of the controller device 500).

FIG. 5G is a schematic of an example exterior layout of the controller device 500, in one or more embodiments. Both a side view and a front view of the controller device 500 are shown in FIG. 5G. For example, in one embodiment, a side of the controller device 500 includes one or more adapters/sockets 502 for one or more antenna connections and/or one or more adapters/sockets 503 for or more Ethernet connections.

FIG. 5H is a schematic of an example interior layout of the controller device 500, in one or more embodiments. FIG. 5I is a schematic of an example network topology of the controller device 500, in one or more embodiments. Table 1 below identifies components of the controller device 500 that are shown in FIGS. 5G-5I.

TABLE 1
Reference Number Component
501 ENCLOSURE, NEMA 4, RAL7035, 24″ × 24″ × 10″
502 BULKHEAD ADAPTER, N-TYPE/F XN-TYPE/F, IP65
503 RJ45 SOCKET, TYPE 4
504 (or SKY-01) ECOPORT TO MODBUS ADAPTER
505 (or REC-01) RECEPTACLE AND POWER CORD, IEC, RIGHT
ANGLE, 13 A
506 (or PSU-01) POWER SUPPLY, QUINT 4, 1-PHASE, 24 VDC, 90 W,
CL2, PUSH-IN
507 (or RAD-01) ROUTER, LTE, TC ROUTER
508 (or ESW-01) ETHERNET SWITCH, UNMANAGED, 10/100, 8-PORT
509 (or PLC-01 or PLC- PLC, ADVANCED UNIT, cPCO MINI DIN, LCD
01 ADVANCED UNIT) DISPLAY
510 SCREW CONNECTORS KIT, ADVANCED PLC
511 SENSOR, NTC
512 (or PLC-01 or PLC- PLC, EXPANSION CARD, cPCO MINI DIN
01 EXPANSION UNIT)
513 SCREW CONNECTORS KIT, EXPANSION CARD
514 CIRCUIT BREAKER, C-CURVE, 1-POLE, 6 A
515 DIN MOUNT RECEPTACLE, SIMPLEX, LED, 15 A
516 RELAY, SPDT, 6 A, LED, 24 VDC RELAY, SPDT, 6 A,
LED, 24 VDC
517 TERMINAL BLOCK, 5.2 MM, BLK
518 TERMINAL BLOCK, 5.2 MM, WHT
519 GROUND, BLOCK, 5.2 MM, GRN/YLW
520 TERMINAL BLOCK, 5.2 MM, RED
521 TERMINAL BLOCK, 5.2 MM, BLU
522 END SECTION
523 END ANCHOR
524 FUSEBLOCK, 6.2 MM, 5 × 20 MM, IND LED, 12-30 V
AC/DC
525 FUSE, 5 × 20 MM, TIME-LAG, 2.5 A
526 FUSE, 5 × 20 MM, TIME-LAG, 1.0 A
527 DIN RAIL, STEEL, 7.5 MM
528 WIRE DUCT, 1.5″ × 3″
529 WIRE DUCT COVER, 1.5″
530 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 1.0 METER
531 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 0.6 METER
532 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 0.4 METER
533 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 0.2 METER
534 CABLE, COAX, SMA/M X N-TYPE/F, 1M

FIGS. 6A-6K illustrate another example controller device 600 for a HPWH system, in one or more embodiments. Specifically, FIG. 6A illustrates a perspective view of an exterior of the controller device 600, in one or more embodiments. FIG. 6B illustrates a perspective view of an interior of the controller device 600, in one or more embodiments. The controller device 600 is integrated into, or implemented as part of, a power distribution and control panel for the HPWH system. The HPWH system comprises at least one storage tank for storing water and at least one heat pump (HP) for heating water from the at least one storage tank.

FIG. 6C is a schematic of an example 120/208V AC power circuit for the controller device 600, in one or more embodiments. FIG. 6D is a schematic of an example 120/208V AC power circuit and an example 24V DC power circuit for the controller device 600, in one or more embodiments. FIG. 6E is a schematic of an example 24V DC power/control circuit for the controller device 600, in one or more embodiments. In one embodiment, incoming power wires to the controller device 600 are kept separate from signal wires (i.e., control wires) or a singular Modbus cable interconnecting the controller device 600 to the temperature sensors and the heat pumps (i.e., units).

FIG. 6F is a schematic of an example PLC I/O for the controller device 600, in one or more embodiments. FIG. 6G is a schematic of an example expansion unit for the controller device 600, in one or more embodiments. FIG. 6H is a schematic of example dry contacts for the controller device 600, in one or more embodiments.

In one embodiment, the client/server data communications protocol Modbus is used to facilitate communication between the at least one heat pump and the controller device 600. Specifically, instead of signal wires, a singular Modbus cable connects each heat pump of the HPWH system to a Modbus network for the HPWH system. This allows additional information relating to the at least one heat pump—such as internal temperatures, motor speeds, etc.—to be accessed and viewed on the Modbus network, e.g., via an end-user application 171, a virtual dashboard accessed via a web browser, an I/O unit 113 (e.g., a PUI or GUI, such as a user interface 622 in FIGS. 6I and 6L, or a PLC 617 in FIGS. 6J and 6M) of the controller device 600, etc.

In one embodiment, if the HPWH system has more than 5 heat pumps, multiple heat pumps are interconnected to each I/O terminal of the controller device 600.

FIG. 6I is a schematic of an example exterior layout of the controller device 600, in one or more embodiments. Both a side view and a front view of the controller device 600 are shown in FIG. 6I. For example, in one embodiment, a side of the controller device 600 includes one or more adapters/sockets 606 for one or more antenna connections and/or one or more adapters/sockets 607 for or more Ethernet connections.

FIG. 6J is a schematic of an example interior layout of the controller device 600, in one or more embodiments. FIG. 6K is a schematic of an example network topology of the controller device 600, in one or more embodiments. Table 2 below identifies components of the controller device 600 that are shown in FIGS. 6I-6K.

TABLE 2
Reference Number Component
601 ENCLOSURE, NEMA 4, RAL7035, 3-PT LATCH, 48″ ×
24″ × 12″
602 BACKPANEL, WHT, 48″ × 24″
603 DOUBLE BIT INSERT
604 DATA POCKET, LARGE
605 WINDOW KIT, DEEP HINGED, RAL7035, 8″ × 8″
WINDOW
606 BULKHEAD ADAPTER, N-TYPE/F X N-TYPE/F, IP65
607 RJ45 SOCKET, TYPE 4
608 DISCONNECT, UL98, 3-POLE, 100 A
609 HANDLE, BLK/RED, TYPE 1/3R/12, 80 MM
610 SHAFT, 6 × 6 MM, 290 MM
611 CIRCUIT BREAKER, K-CURVE, 2-POLE, 15 A
612 CIRCUIT BREAKER, K-CURVE, 1-POLE, 20 A
613 CIRCUIT BREAKER, K-CURVE, 1-POLE, 6 A
614 BUSBAR, 3-POLE, 18-POLE
615 BUSBAR, 3-POLE, 12-POLE
616 RESIDUAL CURRENT DEVICE, 2-POLE, 25 A, 30 MA
TRIP
617 (or PLC-01 or PLC- PLC, ADVANCED UNIT, cPCO MINI DIN, LCD
01 ADVANCED UNIT) DISPLAY
618 SCREW CONNECTORS KIT, ADVANCED PLC
619 SENSOR, NTC
620 (or PLC-01 or PLC- PLC, EXPANSION CARD, cPCO MINI DIN
01 EXPANSION UNIT)
621 SCREW CONNECTORS KIT, EXPANSION CARD
622 (or HMI-01) HMI, GRAPHIC DISPLAY
623 HMI, CABLE, 3M
624 (or SKY-01) ECOPORT TO MODBUS ADAPTER
625 (or REC-01) RECEPTACLE AND POWER CORD, IEC, RIGHT
ANGLE, 13 A
626 (or PSU-01) POWER SUPPLY, QUINT 4, 1-PHASE, 24 VDC, 90 W,
CL2, PUSH-IN
627 (or PP-01) ROUTER, LTE, TC ROUTER
628 (or ESW-01) ETHERNET SWITCH, UNMANAGED, 10/100, 8-PORT
629 DIN MOUNT RECEPTACLE, SIMPLEX, LED, 15 A
630 RELAY, SPDT, 6 A, LED, 24 VDC
631 RELAY, 3PST, 16 A, 24 VDC
632 DIN RAIL, STEEL, 7.5 MM
633 WIRE DUCT, 1.5″ × 3″
634 WIRE DUCT COVER, 1.5″
635 WIRE DUCT, 2″ × 3″
636 WIRE DUCT COVER, 2″
637 WIRE DUCT, 3″ × 3″
638 WIRE DUCT COVER, 3″
639 GROUND BLOCK, PT 16 N-PE, 4-20 AWG, GRN/YLW
640 TERMINAL BLOCK, PT 16 N, 4-20 AWG GRAY
641 END SECTION, D-PT 16 N
642 TERMINAL BLOCK, PT 2.5, 12-26 AWG, WHT
643 TERMINAL BLOCK, PT 2.5, 12-26 AWG, BLU
644 TERMINAL BLOCK, PT 2.5, 12-26 AWG, RED
645 END SECTION, D-ST 2.5
646 GROUND BLOCK, PT 2.5-QUATTRO-PE, 10-24 AWG,
GRN/YLW
647 TERMINAL BLOCK, PT 2.5-QUATTRO, 10-24 AWG,
GRAY
648 END SECTION, D-ST 2.5-QUATTRO
649 END ANCHOR
650 FUSEBLOCK, 6.2 MM, 5 × 20 MM, IND LED, 12-30 V
AC/DC
651 FUSE, 5 × 20 MM, TIME-LAG, 2.5 A
652 FUSE, 5 × 20 MM, TIME-LAG, 1.0 A
653 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 1.0 METER
654 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 0.6 METER
655 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 0.4 METER
656 RJ45 PATCHCORD, UL LISTED, 600 V SHIELDED, CAT
5E 0.2 METER
657 CABLE, COAX, SMA/M X N-TYPE/F, 1M

FIG. 6L illustrates an example exterior user interface 622 positioned at a front of the controller device 600, in one or more embodiments. In one embodiment, the user interface 622 is a PLC remote user interface, consisting of an LCD screen and multiple buttons (e.g., 6 buttons). A user 10 can use the user interface 622 to locally enable/disable the controller device 600 and the HPWH system, view status of the controller device 600 and the HPWH system, adjust configuration settings and operation parameters, and assist in performing equipment service.

FIG. 6M illustrates an example interior user interface 617 positioned inside the controller device 600, in one or more embodiments. In one embodiment, the user interface 617 is a PLC with an integrated user interface. The user interface 617 functions identically to the exterior user interface 622 and typically only used by qualified personnel while performing an update, system repair, or downloading of data logs. For example, on-site code updates and data log downloads are performed through a micro-USB port located in the user interface 617. In one embodiment, online code updates and data log retrievals are available with an active subscription (e.g., provided by the server-side controller system 140).

FIG. 7 is a flowchart of an example process 700 for implementing a cloud-connected controller for a HVAC system, in one or more embodiments. Process block 701 includes collecting real-time data relating to an HVAC system. Process block 702 includes receiving user input provided at least one of locally via a user interface or remotely via the Internet. Process block 703 includes dynamically controlling the HVAC system based on the real-time data and the user input. Process block 704 includes monitoring for one or more alarm conditions relating to the HVAC system. Process block 705 includes providing a remote user with information relating to a status of the HVAC system via the Internet.

In one embodiment, process blocks 701-705 may be performed utilizing one or more components of the system 200, the system 300, controller device 500, and/or the controller device 110.

FIG. 8 is a high-level block diagram showing an information processing system comprising a computer system 1000 useful for implementing the disclosed embodiments. The computer system 1000 includes one or more processors 1001, and can further include an electronic display device 1002 (for displaying video, graphics, text, and other data), a main memory 1003 (e.g., random access memory (RAM)), storage device 1004 (e.g., hard disk drive), removable storage device 1005 (e.g., removable storage drive, removable memory module, a magnetic tape drive, optical disk drive, computer readable medium having stored therein computer software and/or data), user interface device 1006 (e.g., keyboard, touch screen, keypad, pointing device), and a communication interface 1007 (e.g., modem, a network interface (such as an Ethernet card), a communications port, or a PCMCIA slot and card). The main memory 1003 may store instructions that when executed by the one or more processors 1001 cause the one or more processors 1001 to perform one or more process blocks of the process 700.

The communication interface 1007 allows software and data to be transferred between the computer system and external devices. The system 1000 further includes a communications infrastructure 1008 (e.g., a communications bus, cross-over bar, or network) to which the aforementioned devices/modules 1001 through 1007 are connected.

Information transferred via communications interface 1007 may be in the form of signals such as electronic, electromagnetic, optical, or other signals capable of being received by communications interface 1007, via a communication link that carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, a radio frequency (RF) link, and/or other communication channels. Computer program instructions representing the block diagram and/or flowcharts herein may be loaded onto a computer, programmable data processing apparatus, or processing devices to cause a series of operations performed thereon to produce a computer implemented process. In one embodiment, processing instructions for one or more process blocks of process 700 (FIG. 7) may be stored as program instructions on the memory 1003, storage device 1004 and the removable storage device 1005 for execution by the processor 1001.

Embodiments have been described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products. Each block of such illustrations/diagrams, or combinations thereof, can be implemented by computer program instructions. The computer program instructions when provided to a processor produce a machine, such that the instructions, which execute via the processor create means for implementing the functions/operations specified in the flowchart and/or block diagram. Each block in the flowchart/block diagrams may represent a hardware and/or software module or logic. In alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures, concurrently, etc.

The terms “computer program medium,” “computer usable medium,” “computer readable medium”, and “computer program product,” are used to generally refer to media such as main memory, secondary memory, removable storage drive, a hard disk installed in hard disk drive, and signals. These computer program products are means for providing software to the computer system. The computer readable medium allows the computer system to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium. The computer readable medium, for example, may include non-volatile memory, such as a floppy disk, ROM, flash memory, disk drive memory, a CD-ROM, and other permanent storage. It is useful, for example, for transporting information, such as data and computer instructions, between computer systems. Computer program instructions may be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.

As will be appreciated by one skilled in the art, aspects of the embodiments may be embodied as a system, method or computer program product. Accordingly, aspects of the embodiments may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the embodiments may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.

Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.

Computer program code for carrying out operations for aspects of one or more embodiments may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

Aspects of one or more embodiments are described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.

The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

References in the claims to an element in the singular is not intended to mean “one and only” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described exemplary embodiment that are currently known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the present claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or “step for.”

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention.

Though the embodiments have been described with reference to certain versions thereof; however, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.

Claims

What is claimed is:

1. A device comprising:

a network communications unit configured to connect the device to the Internet;

a user interface; and

a controller system configured to:

collect real-time data relating to a heating, ventilation, and air conditioning (HVAC) system that is coupled to the device;

receive user input provided at least one of locally via the user interface or remotely via the Internet;

dynamically control the HVAC system based on the real-time data and the user input;

monitor for one or more alarm conditions relating to the HVAC system; and

provide a remote user with information relating to a status of the HVAC system via the Internet.

2. The device of claim 1, wherein the device is a standalone device that is independent of the HVAC system.

3. The device of claim 1, wherein the device is integrated into a power distribution and control panel for the HVAC system.

4. The device of claim 1, wherein the real-time data comprises one or more temperature readings from one or more temperature sensors positioned within proximity of one or more components of the HVAC system.

5. The device of claim 1, wherein the HVAC system comprises a heat pump water heater (HPWH) system.

6. The device of claim 5, wherein the real-time data comprises a temperature reading of water stored in at least one storage tank of the HPWH system, a temperature reading of water at an inlet of at least one heat pump of the HPWH system, and a temperature reading of ambient temperature surrounding the at least one heat pump.

7. The device of claim 1, wherein each alarm condition triggers an alert that is provided at least one of locally via an alarm indicator of the device or remotely via the Internet.

8. The device of claim 1, wherein the remote user accesses, views, and updates the information relating to the status of the HVAC system via a software application on an electronic device or a virtual dashboard within a web browser.

9. The device of claim 1, wherein the information relating to the status of the HVAC system includes one or more configuration settings of the device and the HVAC system, one or more schedules for the HVAC system, and one or more operating parameters of the HVAC system.

10. A controller system comprising:

a network communications unit configured to connect the controller system to the Internet;

a user interface;

at least one processor; and

a non-transitory processor-readable memory device storing instructions that when executed by the at least one processor causes the at least one processor to perform operations including:

collecting real-time data relating to a heating, ventilation, and air conditioning (HVAC) system that is coupled to the controller system;

receiving user input provided at least one of locally via a user interface or remotely via the Internet;

dynamically controlling the HVAC system based on the real-time data and the user input;

monitoring for one or more alarm conditions relating to the HVAC system; and

providing a remote user with information relating to a status of the HVAC system via the Internet.

11. The controller system of claim 10, wherein the device is a standalone device that is independent of the HVAC system.

12. The controller system of claim 10, wherein the device is integrated into a power distribution and control panel for the HVAC system.

13. The controller system of claim 10, wherein the real-time data comprises one or more temperature readings from one or more temperature sensors positioned within proximity of one or more components of the HVAC system.

14. The controller system of claim 10, wherein the HVAC system comprises a heat pump water heater (HPWH) system.

15. The controller system of claim 14, wherein the real-time data comprises a temperature reading of water stored in at least one storage tank of the HPWH system, a temperature reading of water at an inlet of at least one heat pump of the HPWH system, and a temperature reading of ambient temperature surrounding the at least one heat pump.

16. The controller system of claim 10, wherein each alarm condition triggers an alert that is provided at least one of locally via an alarm indicator of the device or remotely via the Internet.

17. The controller system of claim 10, wherein the remote user accesses, views, and updates the information relating to the status of the HVAC system via a software application on an electronic device or a virtual dashboard within a web browser.

18. The controller system of claim 10, wherein the information relating to the status of the HVAC system includes one or more configuration settings of the device and the HVAC system, one or more schedules for the HVAC system, and one or more operating parameters of the HVAC system.

19. A method comprising:

collecting real-time data relating to a heating, ventilation, and air conditioning (HVAC) system;

receiving user input provided at least one of locally via a user interface or remotely via the Internet;

dynamically controlling the HVAC system based on the real-time data and the user input;

monitoring for one or more alarm conditions relating to the HVAC system; and

providing a remote user with information relating to a status of the HVAC system via the Internet.

20. The method of claim 19, wherein the real-time data comprises one or more temperature readings from one or more temperature sensors positioned within proximity of one or more components of the HVAC system.