System and method for detecting a loose blower wheel of a heating, ventilation, and air conditioning system

Abstract

A method includes operating a motor to impart rotary motion to a load, and receiving electrical data indicative of operation of the motor. The method proceeds by determining, based on the electrical data, a torque value applied by the motor to the load and a speed value of the load, comparing the torque value to a torque threshold, and, in response to the torque value meeting or exceeding the torque threshold, comparing the speed value to a speed threshold. The method concludes by determining, in response to the speed value being less than the speed threshold for at least a predetermined time interval after the torque value meets or exceeds the torque threshold, that the load is loosely coupled to the motor, and generating an indication of the loose coupling condition.

1 . A system comprising: a motor; a load operatively coupled to the motor; 
       a controller operatively coupled to the motor, the controller configured to: (a) receive electrical data indicative of operation of the motor; (b) determine, based on the 
        electrical data, a torque value applied by the motor to the load and a speed value of the load; (c) compare the torque value to a torque threshold, and, in response to the torque value meeting or exceeding the torque threshold, compare the speed value to a speed threshold; (d) determine, in response to the speed value being less than the speed threshold for at least a predetermined time interval after the torque value meets or exceeds the torque threshold, that the load is loosely coupled to the motor; and (e) generate an indication of the loose coupling condition. 
     
     
         2 . The system of  claim 1 , wherein the controller is further configured to, 
       in response to determining that the load is loosely coupled to the motor, cause the motor 
        to shut down. 
     
     
         3 . The system of  claim 1 , wherein the controller is further configured to, 
       in response to determining that the load is loosely coupled to the motor, transmit a notification to a remote device. 
     
     
         4 . The system of  claim 1 , wherein the controller is further configured to determine a type of the load, and wherein the torque threshold, the speed threshold, and 
       the predetermined time interval are selected based on the determined type. 
     
     
         5 . The system of  claim 1 , wherein the electrical data comprises sensed current and sensed voltage supplied to the motor. 
     
     
         6 . The system of  claim 1 , wherein the load comprises a blower wheel. 
     
     
         7 . The system of  claim 1 , wherein the controller is further configured to reset the predetermined time interval and repeat the determination of whether the load is loosely coupled to the motor after an idle period. 
     
     
         8 . A method comprising: (a) operating a motor to impart rotary motion to a load; (b) receiving electrical data indicative of operation of the motor; (c) determining, based on the electrical data, a torque value applied by the motor to the load and a speed value of the load; (d) comparing the torque value to a torque threshold, and, in response 
        to the torque value meeting or exceeding the torque threshold, comparing the speed value to a speed threshold; (e) determining, in response to the speed value being less than the speed threshold for at least a predetermined time interval after the torque value meets or exceeds the torque threshold, that the load is loosely coupled to the motor; and 
       (f) generating an indication of the loose coupling condition. 
     
     
         9 . The method of  claim 8 , further comprising, in response to determining that the load is loosely coupled to the motor, shutting down the motor. 
     
     
         10 . The method of  claim 8 , further comprising, in response to determining 
        that the load is loosely coupled to the motor, transmitting a notification to a remote device. 
     
     
         11 . The method of  claim 8 , further comprising determining a type of the load, wherein the torque threshold, the speed threshold, and the predetermined time 
        interval are selected based on the determined type. 
     
     
         12 . The method of  claim 8 , wherein receiving the electrical data comprises sensing current and voltage supplied to the motor. 
     
     
         13 . The method of  claim 8 , wherein the load comprises a blower wheel. 
     
     
         14 . The method of  claim 8 , further comprising resetting the predetermined time interval and repeating the determination of whether the load is loosely coupled to the motor after an idle period. 
     
     
         15 . The method of  claim 8 , wherein generating the indication of the loose coupling condition comprises displaying a notification on a user interface. 
     
     
         16 . A non-transitory computer-readable medium storing instructions that, 
       when executed by one or more processors, cause the one or more processors to: (a) receive electrical data indicative of operation of a motor configured to impart rotary motion to a load; (b) determine, based on the electrical data, a torque value applied by 
        the motor to the load and a speed value of the load; (c) compare the torque value to a torque threshold, and, in response to the torque value meeting or exceeding the torque threshold, compare the speed value to a speed threshold; (d) determine, in response to the speed value being less than the speed threshold for at least a predetermined time interval after the torque value meets or exceeds the torque threshold, that the load is loosely coupled to the motor; and (e) generate an indication of the loose coupling condition. 
     
     
         17 . The non-transitory computer-readable medium of  claim 16 , wherein the instructions, when executed, further cause the one or more processors to, in response to 
        determining that the load is loosely coupled to the motor, cause the motor to shut down. 
     
     
         18 . The non-transitory computer-readable medium of  claim 16 , wherein the instructions, when executed, further cause the one or more processors to, in response to determining that the load is loosely coupled to the motor, transmit a notification to a 
        remote device. 
     
     
         19 . The non-transitory computer-readable medium of  claim 16 , wherein the instructions, when executed, further cause the one or more processors to determine a type of the load, and wherein the torque threshold, the speed threshold, and the 
        predetermined time interval are selected based on the determined type. 
     
     
         20 . The non-transitory computer-readable medium of  claim 16 , wherein the instructions, when executed, further cause the one or more processors to reset the predetermined time interval and repeat the determination of whether the load is loosely 
        coupled to the motor after an idle period.