As AI – Artificial Intelligence and IoT – continue evolving, the HVAC-R industry benefits from more integrated and advanced solutions. Smart automation, remote monitoring, and predictive analysis, for example, can completely transform the way we project, operate, and maintain heating, ventilation, air conditioning, and refrigeration systems, making them more efficient, reliable, and sustainable.

According to Mário Henrique Canale, president of Asbrav (Associação Sul Brasileira de Refrigeração, Ar Condicionado, Aquecimento e Ventilação), the integration of Artificial Intelligence (AI) and Internet of Things (IoT) in HVAC-R systems is revolutionizing the industry, paving the way for an era of unprecedented energy efficiency and customized user experiences. This innovation represents a significant change in the way we interact and manage these essential systems.

“One of the most noteworthy progresses is the possibility of performing predictive maintenance. Through real-time data analysis and machine learning, the systems may foresee failures and issues before they happen, reducing idle time and maintenance costs. This not only extends the shelf life of the equipment but also ensures that it is operating with maximum efficiency—another innovative application of automatized system optimization. AI algorithms may continuously adjust the HVAC-R settings based on variables such as external temperature, humidity, and use patterns. This results in a more comfortable environment for the users and also reduces energy consumption, aligning with the sustainability goals. Furthermore, smart systems can already perfectly integrate with other residential and commercial automation technologies. This allows more intuitive and convenient control of the climatization systems, improving the general user experience”, explains Canale.

Today, the industry acknowledges the transforming potential of these technologies to boost efficiency, comfort, and sustainability, and it is expected that the systems become smarter, more efficient, and more adaptable to the user's necessities.

Maicon Giesch, Full Gauge Controls development engineer, highlights the integration of Artificial Intelligence (AI) with modern electronic controllers in HVAC-R systems and the transformation of the way these systems are monitored and managed.

“Sensors and electronic controllers equipped with communication patterns perform an essential role in real-time data collection. AI then uses this data for smart analysis and decision-making. By analyzing large volumes of data gathered by different sensors, AI is capable of identifying significant patterns, correlations, and tendencies. This mathematical analysis of the data allows AI to provide valuable insights into the HVAC-R system's performance and possible areas of improvement.

Furthermore, AI may consider several variables and control statuses, carrying out a more complete and precise understanding of the refrigeration system. This approach enables a powerful tool for analysis and monitoring, allowing for more efficient and proactive system management. Using Full Gauge Controls’ solutions offers a comprehensive control and detailed analysis of the refrigeration system. This allows the efficient data analysis and the implementation of autonomous actions in the HVAC-R system, resulting in a robust, efficient, and reliable operation, says Giesch.

Full Gauge’s product line includes a variety of electronic solutions that are connected and integrated with the Sitrad software. The controllers available include solutions for temperature control, humidity, pressure, and electric variables.

IoT and AI play essential roles in predictive maintenance and failure prevention, power efficiency, and reducing environmental impact. By integrating IoT devices, such as temperature and pressure sensors, in refrigeration systems, data about the equipment’s performance can be gathered in real-time.

Full Gauge Controls’ development engineer also adds that using AI enables the learning and real-time analysis of the refrigeration system’s behavior.

“In the case of a cold room, we have a process that operates in a continuous cycle with well-defined triggers and temperature patterns. AI can compare this behavior in real time, and upon detecting deviations, it can alert the user in advance about potential issues. This allows a preventive approach, where performance losses in the refrigeration systems may be observed and corrected before they become serious issues. This performance loss may be attributed to several factors, such as dirty or obstructed condenser, gas leaks, and blocked evaporator, among others. By doing maintenance to optimized HVAC-R systems, it is possible to significantly reduce power consumptions, which results in lower operational costs and a reduction in the environmental impact associated with the system’s operation.”

Among the benefits, Giesch highlights:

• Optimization of the refrigeration process: the integration of controllers and sensors allows continuous monitoring of the temperature and humidity conditions in several locations in the facility. With AI processing the data in real-time, it is possible to adjust the refrigeration systems to optimize the performance automatically;
• Reduction in power consumption: AI may identify power savings opportunities by analyzing use patterns and environmental conditions. This may include adjustments in the refrigeration equipment operation and the implementation of more efficient working schedules, resulting in a significant reduction in the operational costs associated with power consumption;
• Warranty of the storage contagion of perishable products: with continuous monitoring of the condition of refrigeration facilities and AI analyzing the gathered data, users can ensure that perishable products are stored under ideal temperature and humidity conditions. This allows for avoiding losses due to premature deterioration and guarantees the quality of the products over time. Furthermore, the data analysis may help to identify potential issues before they impact the quality of the cold, allowing for a quick and efficient intervention.

With continuous progress, Brazil is on the way to an innovative and intelligent refrigeration paradigm that foresees a positive and long-lasting impact on the HVAC-R industry.

“We have several examples of clients who have benefited from the increasing use of Sitrad. In the supermarket industry, for example, several stores were able to eliminate the loss of perishable products, achieve power savings, and optimize maintenance and operation costs. In a specific case, within a few hours of using the software, the maintenance manager discovered the source of the issue with the freezers that were causing ice cream losses with the graphic reports and suggested immediate improvements.

He identified that the defrost resistor could not perform the complete process and required replacement with a more powerful resistor. Furthermore, the information revealed that the time between the product loading and the opening of the facility prevented the environment from achieving the desired temperature during the period. From that information, the supermarket changed the product loading schedule to an earlier one, allowing the freezer to reach the desired temperature before the client arrived at the store,” mentions Giesch.

Despite its many benefits, implementing AI and IoT in HVAC systems has many challenges, such as the need for initial investment and specialized training to manage these advanced technologies. Another related issue is the extremely important topic of data privacy and safety gathered by smart systems.

Giesch highlights the digitalization of processes as an essential point for successfully implementing Artificial Intelligence in refrigeration and air conditioning systems.

“The adoption of electronic controllers and sensors with connectivity allows the gathering of a large amount of data, which is essential for the effectiveness of AI algorithms in optimizing performance and detecting anomalies. By replacing mechanical or analog control solutions, such as pressure gauges and thermal gauges, for digital solutions with connectivity, companies may get substantial benefits, such as higher precision and repeatability in processes. The capacity to remotely control these systems through digital interfaces offers higher flexibility and operational efficiency. However, the culture change and acceptance of these new technologies may also bring out significant challenges. The workers' resistance to change and the need for adequate training to use the new solutions are important aspects to be considered in the process. Therefore, to overcome this challenge, it is essential to invest in training and awareness programs, highlighting the benefits of digitalization and the adoption of AI technologies in refrigeration and air conditioning systems. Furthermore, it is important to ensure that the chosen digital solutions are robust, safe, and compatible with the specific requirements of the industry in order to guarantee a successful transition to a more digitalized and efficient environment,” he concludes.