Managing the effectiveness of repairs in refrigeration assets
A method and an apparatus are provided that may be applicable to refrigeration assets, including refrigeration plants and cold-storage facilities comprising large numbers of refrigeration assets. The performance of refrigerators and refrigeration devices may be monitored based on temperature and electrical current and other measurements known or deemed to be correlated with refrigeration performance. Refrigeration assets in need of repair may be identified and a repair process may be specified, classified, managed and optimized. The immediate effectiveness and long-term persistence of repairs may be determined over time. The refrigeration assets may be classified according to reliability, performance, make, model and manufacturer. The effectiveness of repairs may be classified based on measured performance results following repairs. Service providers, including organizations, companies or individuals providing repair and other services, may be evaluated for the effectiveness and persistence of repair results using benchmarks and other quantitative evaluation methods.
1. A method of controlling a network of refrigeration systems, comprising:
receiving first measurements captured by sensors in a plurality of refrigeration assets, each sensor being configured to continuously measure temperature or electrical current during each thermodynamic cycle of a corresponding refrigeration asset, wherein the first measurements include temperature or electrical current measurements obtained by the each sensor as samples taken at a frequency calculated to determine a fundamental frequency of the refrigeration cycle of the corresponding refrigeration asset;
identifying a first feature of the first measurements that indicates (i) onset of failure of a first refrigeration asset when the first feature comprises a failure pattern identified in measurements obtained by at least one sensor that is associated with the first refrigeration asset, or (ii) instability in a component of the first refrigeration asset;
initiating a service or repair procedure configured to prevent failure of the first refrigeration asset;
receiving second measurements captured by the sensors in the plurality of refrigeration assets after the first refrigeration asset has been repaired; and
determining whether a second feature present in the second measurements indicates that the first refrigeration asset is operating at an optimal performance level, the second feature corresponding to a healthy pattern identified in the first measurements and the second measurements, wherein the healthy pattern is associated with one or more other refrigeration assets operating at the optimal performance level.
2. The method of claim 1 , wherein the first feature comprises cycle variance corresponding to variance in duration of thermodynamic cycles of the first refrigeration asset.
3. The method of claim 1 , wherein the failure pattern comprises a pattern of change in cycles of temperature or electrical current associated with the first refrigeration asset.
4. The method of claim 1 , wherein the sensors comprise a vibration sensor configured to detect vibration of a compressor in the first refrigeration asset that indicates that the compressor is cycling on or cycling off.
5. The method of claim 1 , wherein the one or more healthy patterns correspond to patterns identified in prior measurements captured from a refrigeration asset that is performing at the optimal level and that is from the same type of refrigeration asset as the first refrigeration asset.
6. The method of claim 1 , wherein initiating the repair procedure comprises:
identifying the repair procedure to a repair technician before the repair technician is dispatched to service or repair the first refrigeration asset, the repair procedure identifying actions to be taken or omitted and timing of the actions to be taken or omitted.
7. The method of claim 6 , wherein the first measurements are received before the repair technician is dispatched to service or repair the first refrigeration asset.
8. The method of claim 1 , wherein a smart sensor in the first refrigeration asset is configured to communicate statistical information related to performance or energy consumption by the first refrigeration asset based on an analysis of measurements captured by the smart sensor.
9. The method of claim 1 , wherein identifying the first feature comprises:
analyzing a plurality of sensor streams, each sensor stream comprising measurements obtained from a sensor corresponding to one of the plurality of refrigeration assets.
10. The method of claim 1 , wherein the fundamental frequency of the refrigeration cycle of the corresponding refrigeration asset corresponds to a fundamental frequency of a temperature cycle within the corresponding refrigeration asset.
11. An apparatus for managing repair of a refrigeration system, comprising:
a controller comprising at least one processing circuit configured to receive measurements captured at a plurality of refrigeration assets; and
an analyzer comprising at least one processing circuit configured to:
receive first measurements captured by sensors in a plurality of refrigeration assets, each sensor being configured to continuously measure temperature or electrical current during each thermodynamic cycle of a corresponding refrigeration asset, wherein the first measurements include temperature or electrical current measurements obtained by the each sensor as samples taken at a frequency calculated to determine a fundamental frequency of the refrigeration cycle of the corresponding refrigeration asset;
identify a first feature of the first measurements that indicates (i) onset of failure of a first refrigeration asset when the first feature comprises a failure pattern identified in measurements obtained by at least one sensor that is associated with the first refrigeration asset, or (ii) instability in a component of the first refrigeration asset;
initiate a service or repair procedure configured to prevent failure of the first refrigeration asset;
receive second measurements captured by the sensors in the plurality of refrigeration assets after the first refrigeration asset has been repaired; and
determine whether a second feature present in the second measurements indicates that the first refrigeration asset is operating at an optimal performance level, the second feature corresponding to a healthy pattern identified in the first measurements and the second measurements, wherein the healthy pattern is associated with one or more other refrigeration assets operating at the optimal performance level.
12. The apparatus of claim 11 , wherein the first feature comprises cycle variance corresponding to variance in duration of thermodynamic cycles of the first refrigeration asset.
13. The apparatus of claim 11 , wherein the failure pattern comprises a pattern of change in cycles of temperature or electrical current associated with the first refrigeration asset.
14. The apparatus of claim 11 , wherein the sensors comprise a vibration sensor configured to detect vibration of a compressor in the first refrigeration asset that indicates that the compressor is cycling on or cycling off.
15. The apparatus of claim 11 , wherein the one or more healthy patterns correspond to patterns identified in prior measurements captured from a refrigeration asset that is performing at the optimal level and that is from the same type of refrigeration asset as the first refrigeration asset.
16. The apparatus of claim 11 , wherein the at least one processing circuit is further configured to:
identify the repair procedure to a repair technician before the repair technician is dispatched to service or repair the first refrigeration asset, the repair procedure identifying actions to be taken or omitted and timing of the actions to be taken or omitted.
17. The apparatus of claim 16 , wherein the first measurements are received before the repair technician is dispatched to service or repair the first refrigeration asset.
18. The apparatus of claim 11 , wherein a smart sensor in the first refrigeration asset is configured to communicate statistical information related to performance or energy consumption by the first refrigeration asset based on an analysis of measurements captured by the smart sensor.
19. The apparatus of claim 11 , wherein the fundamental frequency of the refrigeration cycle of the corresponding refrigeration asset corresponds to a fundamental frequency of a temperature cycle within the corresponding refrigeration asset.
20. The apparatus of claim 11 , wherein the at least one processing circuit is further configured to:
analyze a plurality of sensor streams, each sensor stream comprising measurements obtained from a sensor corresponding to one of the plurality of refrigeration assets.
21. A non-transitory processor-readable storage medium having one or more instructions which, when executed by at least one processing circuit, cause the at least one processing circuit to:
receive first measurements captured by sensors in a plurality of refrigeration assets, each sensor being configured to continuously measure temperature or electrical current during each thermodynamic cycle of a corresponding refrigeration asset, wherein the first measurements include temperature or electrical current measurements obtained by the each sensor as samples taken at a frequency calculated to determine a fundamental frequency of the refrigeration cycle of the corresponding refrigeration asset;
identify a first feature of the first measurements that indicates (i) onset of failure of a first refrigeration asset when the first feature comprises a failure pattern identified in measurements obtained by at least one sensor that is associated with the first refrigeration asset, or (ii) instability in a component of the first refrigeration asset;
initiate a service or repair procedure configured to prevent failure of the first refrigeration asset;
receive second measurements captured by the sensors in the plurality of refrigeration assets after the first refrigeration asset has been repaired; and
determine whether a second feature present in the second measurements indicates that the first refrigeration asset is operating at an optimal performance level, the second feature corresponding to a healthy pattern identified in the first measurements and the second measurements, wherein the healthy pattern is associated with one or more other refrigeration assets operating at the optimal performance level.
22. The processor-readable storage medium of claim 21 , wherein the first feature comprises cycle variance corresponding to variance in duration of thermodynamic cycles of the first refrigeration asset.
23. The processor-readable storage medium of claim 21 , wherein the fundamental frequency of the refrigeration cycle of the corresponding refrigeration asset corresponds to a fundamental frequency of a temperature cycle within the corresponding refrigeration asset.