IP Library › Granted Patent US 12,242,259
Granted Patent B2
US 12,242,259 · App. 16/943,781 · Granted Mar 4, 2025

Model predictive maintenance system with event or condition based performance

Inventors: Mohammad N. Elbsat (Milwaukee, WI); Michael J. Wenzel (Oak Creek, WI); Farhad Balali (Milwaukee, WI); Robert D. Turney (Watertown, WI)
G05B23/0283G05B23/024G16Y10/80G16Y20/30G16Y40/20G16Y40/40
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Quick Facts
Patent No.
US 12,242,259
App. No.
16/943,781
Granted
Mar 4, 2025
Kind
B2
Abstract

A model predictive maintenance (MPM) system for building equipment includes one or more processing circuits including one or more processors and memory storing instructions that, when executed by the one or more processors, cause the one or more processors to perform operations. The operations include obtaining one or more performance indicators for the building equipment and determining whether a trigger condition has been satisfied based on the one or more performance indicators. The operations include triggering a model predictive maintenance process to generate a maintenance schedule for the building equipment in response to determining that the trigger condition has been satisfied. The operations include initiating a maintenance activity for the building equipment in accordance with the maintenance schedule.

Claims (89)

1. A model predictive maintenance (MPM) system for building equipment, the MPM system comprising:

one or more processing circuits comprising one or more processors and memory storing instructions that, when executed by the one or more processors, cause the one or more processors to perform operations comprising:

at a first time, predicting a future state of the building equipment predicted to occur at a second time after the first time;

obtaining one or more performance indicators for the building equipment indicating an actual state of the building equipment at a second time;

determining whether a trigger condition has been satisfied based on the one or more performance indicators by comparing the actual state of the building equipment at the second time with the predicted future state of the building equipment predicted to occur at the second time;

triggering a model predictive maintenance process to generate a maintenance schedule for the building equipment and operating decisions for the building equipment in response to determining that the trigger condition has been satisfied, wherein the model predictive maintenance process comprises:

predicting a resource consumption of the building equipment over an optimization period as a function of an estimated degradation state of the building equipment;

defining a cost of operating the building equipment over the optimization period as a function of the predicted resource consumption;

defining a cost of performing maintenance on the building equipment over the optimization period as a function of the maintenance schedule for the building equipment; and

optimizing an objective function including the cost of operating the building equipment and the cost of performing maintenance on the building equipment to determine the maintenance schedule;

initiating a maintenance activity for the building equipment in accordance with the maintenance schedule; and

controlling the building equipment by generating electronic control signals based on the operating decisions for the building equipment and causing the building equipment to affect a variable state or condition in a building using the electronic control signals.

2. The MPM system of claim 1 , wherein the one or more performance indicators comprise at least one of an estimated current degradation of the building equipment, a predicted future degradation of the building equipment, or a performance variable of the building equipment, wherein the operations further comprise:

comparing the estimated current degradation, the predicted future degradation, or the performance variable of the building equipment to a corresponding threshold; and

determining that the trigger condition has been satisfied in response to the estimated current degradation, the predicted future degradation, or the performance variable crossing the corresponding threshold.

3. The MPM system of claim 1 , wherein the one or more performance indicators comprise a rate of change of at least one of an estimated current degradation of the building equipment, a predicted future degradation of the building equipment, or a performance variable of the building equipment, wherein the operations further comprise:

comparing the rate of change of the estimated current degradation, the predicted future degradation, or the performance variable of the building equipment to a corresponding threshold rate of change; and

determining that the trigger condition is satisfied in response to the rate of change of the estimated current degradation, the predicted future degradation, or the performance variable crossing the corresponding threshold rate of change.

4. The MPM system of claim 1 , wherein the operations further comprise:

determining a variance or a covariance of at least one of the one or more performance indicators of the building equipment;

comparing the variance or covariance to a corresponding variance or covariance threshold;

determining that the trigger condition is satisfied in response to the variance or the covariance and the corresponding variance or covariance threshold.

5. The MPM system of claim 1 , wherein the predicted future state of the building equipment is a previously predicted future degradation of the building equipment and the actual state of the building equipment is an actual current degradation of the building equipment, wherein the operations further comprise:

determining a difference between the previously predicted future degradation of the building equipment and the actual current degradation of the building equipment for the second time, the second time being a corresponding time step;

comparing the difference to a corresponding difference threshold;

determining that the trigger condition is satisfied in response to the difference and the corresponding difference threshold.

6. The MPM system of claim 1 , wherein the operations further comprise:

receiving an output of a fault detection circuit, the fault detection circuit configured to receive time series data and perform at least one of a peer detection method, a temporal detection method, and an artificial intelligence detection method to generate the output; and

determining that the trigger condition is satisfied in response to the output indicating a fault of the building equipment.

7. A method for determining optimal maintenance of building equipment, the method comprising:

at a first time, predicting a future state of the building equipment predicted to occur at a second time after the first time;

obtaining one or more performance indicators for the building equipment indicating an actual state of the building equipment at a second time;

determining whether a trigger condition has been satisfied based on the one or more performance indicators by comparing the actual state of the building equipment at the second time with the predicted future state of the building equipment predicted to occur at the second time;

triggering a model predictive maintenance process to generate a maintenance schedule for the building equipment and operating decisions for the building equipment in response to determining that the trigger condition has been satisfied, wherein the model predictive maintenance process comprises:

predicting a resource consumption of the building equipment over an optimization period as a function of an estimated degradation state of the building equipment;

defining a cost of operating the building equipment over the optimization period as a function of the predicted resource consumption;

defining a cost of performing maintenance on the building equipment over the optimization period as a function of the maintenance schedule for the building equipment; and

optimizing an objective function including the cost of operating the building equipment and the cost of performing maintenance on the building equipment to determine the maintenance schedule;

initiating a maintenance activity for the building equipment in accordance with the maintenance schedule; and

controlling the building equipment by generating electronic control signals based on the operating decisions for the building equipment and causing the building equipment to affect a variable state or condition in a building using the electronic control signals.

8. The method of claim 7 , wherein the one or more performance indicators comprise at least one of an estimated current degradation of the building equipment, a predicted future degradation of the building equipment, or a performance variable of the building equipment, wherein the method further comprises:

comparing the estimated current degradation, the predicted future degradation, or the performance variable of the building to a corresponding threshold; and

determining that the trigger condition has been satisfied in response to the estimated current degradation, the predicted future degradation, or the performance variable crossing the corresponding threshold.

9. The method of claim 7 , wherein the one or more performance indicators comprise a rate of change of at least one of an estimated current degradation of the building equipment, a predicted future degradation of the building equipment, or a performance variable of the building equipment, wherein the method further comprises:

comparing the rate of change of the estimated current degradation, the predicted future degradation, or the performance variable of the building equipment to a corresponding threshold rate of change; and

determining that the trigger condition has been satisfied in response to the rate of change of the estimated current degradation, the predicted future degradation, or the performance variable crossing the corresponding threshold rate of change.

10. The method of claim 7 , further comprising:

determining a variance or a covariance of at least one of the one or more performance indicators of the building equipment;

comparing the variance or covariance to a corresponding variance or covariance threshold;

determining that the trigger condition is satisfied in response to the variance or the covariance crossing the corresponding variance or covariance threshold.

11. The method of claim 7 , wherein the predicted future state of the building equipment is a previously predicted future degradation of the building equipment and the actual state of the building equipment is an actual current degradation of the building equipment, wherein the method further comprises:

determining a difference between the predicted future degradation of the building equipment and the actual current degradation of the building equipment for the second time, the second time being a corresponding time step;

comparing the difference to a corresponding difference threshold;

determining that the trigger condition is satisfied in response to the difference crossing the corresponding difference threshold.

12. The method of claim 7 , further comprising:

receiving an output of a fault detection circuit, the fault detection circuit configured to receive time series data and perform at least one of a peer detection method, a temporal detection method, and an artificial intelligence detection method to generate the output; and

determining that the trigger condition is satisfied in response to the output indicating a fault of the building equipment.

13. The method of claim 7 , wherein the model predictive maintenance process further comprises:

predicting an energy consumption of the building equipment over the optimization period as a function of an estimated efficiency of the building equipment;

defining the cost of operating the building equipment over the optimization period as a function of the predicted energy consumption;

defining the cost of performing maintenance on the building equipment over the optimization period as a function of an estimated reliability of the building equipment; and

optimizing the objective function including the cost of operating the building equipment and the cost of performing maintenance on the building equipment to determine the maintenance schedule.

14. A model predictive maintenance (MPM) controller for building equipment, the MPM controller comprising:

one or more processing circuits comprising one or more processors and memory storing instructions that, when executed by the one or more processors, cause the one or more processors to perform operations comprising:

determining whether a trigger condition has been satisfied based on one or more time-varying inputs to the MPM controller and at least one time-varying threshold; and

triggering a model predictive maintenance process to generate a maintenance schedule for the building equipment and operating decisions for the building equipment in response to determining that the trigger condition has been satisfied, wherein the model predictive maintenance process comprises:

predicting a resource consumption of the building equipment over an optimization period as a function of an estimated degradation state of the building equipment;

defining a cost of operating the building equipment over the optimization period as a function of the predicted resource consumption;

defining a cost of performing maintenance on the building equipment over the optimization period as a function of the maintenance schedule for the building equipment; and

optimizing an objective function including the cost of operating the building equipment and the cost of performing maintenance on the building equipment to determine the maintenance schedule; and

initiating a maintenance activity for the building equipment in accordance with the maintenance schedule; and

controlling the building equipment by generating electronic control signals based on the operating decisions for the building equipment and causing the building equipment to affect a variable state or condition in a building using the electronic control signals.

15. The MPM controller of claim 14 , wherein the one or more time-varying inputs comprise at least one of an estimated current degradation of the building equipment, a predicted future degradation of the building equipment, or a performance variable of the building equipment, wherein the operations further comprise:

comparing the estimated current degradation, the predicted future degradation, or the performance variable of the building equipment to a corresponding threshold; and

determining that the trigger condition is satisfied in response to the comparison between the estimated current degradation, the predicted future degradation, or the performance variable crossing the corresponding threshold.

16. The MPM controller of claim 14 , wherein the one or more time-varying inputs comprise a rate of change of at least one of an estimated current degradation of the building equipment, a predicted future degradation of the building equipment, or a performance variable of the building equipment, wherein the operations further comprise:

comparing the rate of change of the estimated current degradation, the predicted future degradation, or the performance variable of the building equipment to a corresponding threshold rate of change; and

determining that the trigger condition is satisfied in response to the comparison between the rate of change of the estimated current degradation, the predicted future degradation, or the performance variable crossing the corresponding threshold rate of change.

17. The MPM controller of claim 14 , wherein the operations further comprise:

determining a variance or a covariance of at least one of the one or more time-varying inputs;

comparing the variance or covariance to a corresponding variance or covariance threshold;

determining that the trigger condition is satisfied in response to the variance or the covariance crossing the corresponding variance or covariance threshold.

18. The MPM controller of claim 14 , wherein the one or more time-varying inputs comprise a previously predicted future degradation of the building equipment and an estimated current degradation of the building equipment, wherein the operations further comprise:

determining a difference between the previously predicted future degradation of the building equipment and the estimated current degradation of the building equipment for a corresponding time step;

comparing the difference to a corresponding difference threshold;

determining that the trigger condition is satisfied in response to the difference crossing the corresponding difference threshold.

19. The MPM controller of claim 14 , wherein the operations further comprise:

receiving an output of a fault detection circuit, the fault detection circuit configured to receive time series data and perform a peer detection method, a temporal detection method, and an artificial intelligence detection method to generate the output; and

determining that the trigger condition is satisfied in response to the output indicating a fault of the building equipment.

Assignments (3)
NUNC PRO TUNC ASSIGNMENT Recorded Jan 22, 2025
From: JOHNSON CONTROLS TECHNOLOGY COMPANY
To: JOHNSON CONTROLS TYCO IP HOLDINGS LLP
Reel/Frame 069970/0027 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 9, 2024
From: JOHNSON CONTROLS TYCO IP HOLDINGS LLP
To: TYCO FIRE & SECURITY GMBH
Reel/Frame 067056/0552 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 14, 2020
From: ELBSAT, MOHAMMAD N.; WENZEL, MICHAEL J.; BALALI, FARHAD; TURNEY, ROBERT D.
To: JOHNSON CONTROLS TECHNOLOGY COMPANY
Reel/Frame 054056/0049 →
Continuity (5)
Continuation In Part 16899220 · Jun 11, 2020
Continuation In Part 15895836 · Feb 13, 2018
Provisional Application 62883508 · Aug 6, 2019
Provisional Application 62511113 · May 25, 2017
Related Publication 20200356087A1 · Nov 12, 2020
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