IP Library Granted Patent US 12,422,158
Granted Patent B2
US 12,422,158 · App. 17/823,150 · Granted Sep 23, 2025

Energy management and smart thermostat learning methods and control systems

Inventors: Brian Richard Butler (Centerville, OH); Kevin Patrick Hallinan (Dayton, OH); Kefan Huang (Miamisburg, OH); Abdulrahman Alanezi (Al-Jubail, SA); David Alexander Alfano (Lancaster, PA); Andrew M. Welch (Franklin, OH); Stuart Keith Morgan (West Chester, OH)
Assignee: Copeland Comfort Control LP
F24F11/63F24F11/30G05B13/027F24F2130/10
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Quick Facts
Patent No.
US 12,422,158
App. No.
17/823,150
Filed
Aug 30, 2022
Granted
Sep 23, 2025
Kind
B2
Art Unit
2115
USPC
700/278
Abstract

A method of HVAC system performance monitoring using a computing device connected to at least one thermostat of an HVAC system in a building includes receiving thermostat data from the thermostat, the thermostat data including temperature setpoint data, measured building temperature data, and HVAC operation data for a time period. Weather data is received from a weather service for the time period, and the thermostat data is synchronized with the weather data with respect to time. At least one machine learning model is trained using the synchronized thermostat and weather data, and performance of the HVAC system over time is monitored using the trained machine learning model.

Claims (50)

1. A method of HVAC system performance monitoring using a computing device connected to at least one thermostat of an HVAC system in a building including a fan, the method comprising:

receiving thermostat data from the thermostat, the thermostat data including temperature setpoint data, measured building temperature data, and HVAC operation data for an initial time period, the HVAC operation data including usage data for the HVAC system fan;

receiving weather data from a weather service for the initial time period;

synchronizing the thermostat data with the weather data with respect to time;

determining, by interpolation, intermediate data between any data that is non-uniformly spaced with respect to time in the synchronized thermostat and weather data;

inserting the intermediate data into the synchronized thermostat and weather data to generate synchronized thermostat and weather data that is uniformly spaced;

training at least one machine learning model using the synchronized thermostat and weather data;

monitoring performance of the HVAC system over time using the trained machine learning model by repeatedly:

receiving weather data from the weather service for a future time period after the initial time period;

receiving additional thermostat data for the future time period from the thermostat, the additional thermostat data including temperature setpoint data, measured building temperature data, and HVAC operation data for the future time period;

determining, based on the received additional thermostat data, an actual amount of heating or cooling and an actual amount of fan usage for the future time period;

determining, using the trained machine learning model and based on the received weather data for the future time period, an expected amount of heating or cooling and an expected amount of fan usage for the future time period with the HVAC system set at the determined temperature setpoint;

comparing the actual amount of heating or cooling to the expected amount of heating or cooling;

comparing the actual amount of fan usage to the expected amount fan usage; and

determining that the performance of the HVAC system has decreased when the actual amount of heating or cooling differs from the expected amount of heating or cooling by more than a first threshold amount or the actual amount of fan usage differs from the expected amount of fan usage by more than a second threshold amount; and

outputting an alert when the monitored performance of the HVAC system is determined to have decreased.

2. The method of claim 1 , wherein receiving weather data from the weather service for the future time period, receiving additional thermostat data from the thermostat during the future time period, using the trained machine learning model to determine the predicted HVAC operation during the future time period based on the weather data for the future time period, and comparing the additional thermostat data for the future time period to the predicted HVAC operation for the future time period are performed once per day.

3. The method of claim 1 , wherein training at least one machine learning model using the synchronized thermostat and weather data comprises training a regression based model using the synchronized thermostat and weather data.

4. The method of claim 1 , wherein training at least one machine learning model using the synchronized thermostat and weather data comprises training a long short-term memory deep learning neural network dynamic model using the synchronized thermostat and weather data.

5. The method of claim 1 , wherein outputting an alert when the monitored performance of the HVAC system is determined to have decreased comprises outputting an alert to a service provider associated with the building.

6. The method of claim 1 , further comprising servicing the HVAC system in response to the output alert.

7. The method of claim 1 , wherein training at least one machine learning model using the synchronized thermostat and weather data comprises training an encoder-decoder long short-term memory deep learning neural network dynamic model using the synchronized thermostat and weather data.

8. The method of claim 1 , wherein training at least one machine learning model using the synchronized thermostat and weather data comprises training a distributed random forest model using the synchronized thermostat and weather data.

9. The method of claim 1 , wherein training at least one machine learning model using the synchronized thermostat and weather data comprises training a global boosting model using the synchronized thermostat and weather data.

10. A performance monitoring system comprising:

a communication interface, the communication interface operable to communicatively couple the performance monitoring system to at least one thermostat of an HVAC system in a building including a fan,

a memory; and

a processor coupled to the communication interface and the memory, the memory storing instructions that when executed by the processor cause the processor to:

receive thermostat data from the thermostat through the communication interface, the thermostat data including temperature setpoint data, measured building temperature data, and HVAC operation data for an initial time period;

receive weather data from a weather service for the initial time period;

synchronize the thermostat data with the weather data with respect to time;

determine, by interpolation, intermediate data between any data that is non-uniformly spaced with respect to time in the synchronized thermostat and weather data;

insert the intermediate data into the synchronized thermostat and weather data to generate synchronized thermostat and weather data that is uniformly spaced;

train at least one machine learning model using the synchronized thermostat and weather data;

monitor performance of the HVAC system over time using the trained machine learning model by repeatedly:

receiving weather data from the weather service for a future time period after the initial time period;

receiving additional thermostat data for the future time period from the thermostat, the additional thermostat data including temperature setpoint data, measured building temperature data, and HVAC operation data for the future time period;

determining, based on the received additional thermostat data, an actual amount of heating or cooling and an actual amount of fan usage for the future time period;

determining, using the trained machine learning model and based on the received weather data for the future time period, an expected amount of heating or cooling and an expected amount of fan usage for the future time period with the HVAC system set at the determined temperature setpoint;

comparing the actual amount of heating or cooling to the expected amount of heating or cooling;

comparing the actual amount of fan usage to the expected amount of fan usage; and

determining that the performance of the HVAC system has decreased when the actual amount of heating or cooling differs from the expected amount of heating or cooling by more than a first threshold amount or the actual amount of fan usage differs from the expected amount of fan usage by more than a second threshold amount; and

output an alert when the monitored performance of the HVAC system is determined to have decreased.

11. The performance monitoring system of claim 10 , wherein the instructions cause the processor to receive weather data from the weather service for the future time period, receive additional thermostat data from the thermostat during the future time period, use the trained machine learning model to determine the predicted HVAC operation during the future time period based on the weather data for the future time period, and compare the additional thermostat data for the future time period to the predicted HVAC operation for the future time period once per day.

12. The performance monitoring system of claim 10 , wherein the instructions cause the processor to train at least one machine learning model using the synchronized thermostat and weather data by training a regression based model using the synchronized thermostat and weather data.

13. The performance monitoring system of claim 10 , wherein the instructions cause the processor to train at least one machine learning model using the synchronized thermostat and weather data by training a long short-term memory deep learning neural network dynamic model using the synchronized thermostat and weather data.

14. The performance monitoring system of claim 10 , wherein the instructions cause the processor to output the alert when the monitored performance of the HVAC system is determined to have decreased by outputting an alert to a service provider associated with the building.

15. The performance monitoring system of claim 10 , wherein the instructions cause the processor to train at least one machine learning model using the synchronized thermostat and weather data by training an encoder-decoder long short-term memory deep learning neural network dynamic model using the synchronized thermostat and weather data.

16. The performance monitoring system of claim 10 , wherein the instructions cause the processor to train at least one machine learning model using the synchronized thermostat and weather data by training a distributed random forest model using the synchronized thermostat and weather data.

17. The performance monitoring system of claim 10 , wherein the instructions cause the processor to train at least one machine learning model using the synchronized thermostat and weather data by training a global boosting model using the synchronized thermostat and weather data.

Assignments (6)
SECURITY INTEREST Recorded Feb 4, 2025
From: COPELAND COMFORT CONTROL LP
To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 070099/0767 →
SECURITY INTEREST Recorded Feb 4, 2025
From: COPELAND COMFORT CONTROL LP
To: ROYAL BANK OF CANADA, AS COLLATERAL AGENT
Reel/Frame 070099/0957 →
SECURITY INTEREST Recorded Feb 3, 2025
From: COPELAND LP; COPELAND SCROLL COMPRESSORS LP; COPELAND INDUSTRIAL LP; COPELAND COMFORT CONTROL LP; COPELAND COLD CHAIN LP
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION, AS NOTES COLLATERAL AGENT
Reel/Frame 070568/0920 →
SECURITY INTEREST Recorded Jul 9, 2024
From: COPELAND COMFORT CONTROL LP
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION, AS NOTES COLLATERAL AGENT
Reel/Frame 068255/0466 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 9, 2023
From: EMERSON ELECTRIC CO.
To: COPELAND COMFORT CONTROL LP
Reel/Frame 064531/0480 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 14, 2022
From: BUTLER, BRIAN RICHARD; HALLINAN, KEVIN PATRICK; HUANG, KAFAN; ALANEZI, ABDULRAHMAN; ALFANO, DAVID ALEXANDER; WELCH, ANDREW M.; MORGAN, STUART KEITH
To: EMERSON ELECTRIC CO.
Reel/Frame 061093/0175 →