Patent Publication Number: US-2016231039-A1

Title: Air conditioner

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority from Korean Patent Application No. 10-2015-0019743, filed Feb. 9, 2015, the subject matter of which is incorporated herein by reference. 
     BACKGROUND 
     1. Field 
     Embodiments may relate to an air conditioner, and more particularly to an air conditioner that is capable of determining an operation state or abnormality of a compressor or a fan in the air conditioner. 
     2. Background 
     An air conditioner may discharge cool air or hot air into a room to adjust indoor temperature and to purify indoor air, thereby providing a more comfortable indoor environment. The air conditioner may include an indoor unit that is installed in the room, and an outdoor unit for supplying a refrigerant to the indoor unit. The indoor unit may include an indoor heat exchanger. The outdoor unit may include a compressor and an outdoor heat exchanger. 
     The air conditioner may be controlled in a state in which the air conditioner is divided into the indoor unit, which includes the indoor heat exchanger, and the outdoor unit, which includes the compressor and the outdoor heat exchanger. More specifically, the compressor or the heat exchanger may be controlled to be powered on or off to operate the air conditioner. The air conditioner may be configured such that at least one indoor unit is connected to the outdoor unit. Depending on a required operation state of the air conditioner, the refrigerant may be supplied to the indoor unit such that the air conditioner operates in a cooling mode or a heating mode. 
     The air conditioner may perform a cooling operation or a heating operation based on flow of the refrigerant. In the cooling operation, a high-temperature, high-pressure liquid refrigerant from the compressor (in the outdoor unit) may be supplied to the indoor unit via the outdoor heat exchanger (in the outdoor unit). In the indoor heat exchanger (in the indoor unit), the refrigerant is expanded and evaporated. As a result, temperature of the surrounding air is lowered. As an indoor unit fan is rotated, cool air is discharged into the room. On the other hand, in the heating mode, a high-temperature, high-pressure gas refrigerant from the compressor (in the outdoor unit) is supplied to the indoor unit. In the indoor heat exchanger (in the indoor unit), the high-temperature, high-pressure gas refrigerant is liquefied and discharged. As a result, temperature of the surrounding air is raised. As an indoor unit fan is rotated, hot air is discharged into the room. 
     The air conditioner with the above-described configuration may not operate any longer if the compressor or a fan motor is abnormal. 
     Insulation resistance of the compressor or the fan motor may be measured in order to determine whether the compressor of the air conditioner is abnormal. However, this measurement may be possible only after the compressor or the fan motor of the air conditioner has broken down. However, it may not be possible to monitor the lifespan of the compressor or the fan motor or progress of the breakdown of the compressor or the fan motor before the compressor or the fan motor of the air conditioner has broken down. 
     Additionally, since the insulation resistance of the compressor or the fan motor is measured, it is possible to sense only abnormality generated in windings of the compressor or the fan motor; however, it may not be possible to sense breakdowns generated due to other causes. 
     That is, in a situation in which the compressor is abnormal, the air conditioner may not perform cooling and heating operations. Accordingly, there is a high necessity for a method of monitoring sensing abnormality of the compressor and coping with the sensed abnormality of the compressor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Arrangements and/or embodiments may be described in detail with reference to the following drawings in which like reference numerals refer to like elements and wherein: 
         FIG. 1  is a view schematically showing an air conditioner according to an example embodiment; 
         FIG. 2  is a view schematically showing an outdoor unit and an indoor unit according to an example embodiment; 
         FIG. 3  is a block diagram showing a control construction for sensing abnormality of a compressor or a fan motor of an air conditioner according to an example embodiment; 
         FIG. 4  is a view schematically showing a sensing unit for sensing abnormality of the compressor or the fan motor according to an example embodiment; 
         FIG. 5  is a view showing an installation example of a sensing unit of an air conditioner according to an example embodiment; and 
         FIG. 6  is a view showing an example of a warning output from an air conditioner according to an example embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Advantages and features of embodiments and the way of achieving them may become apparent with reference to embodiments described below in conjunction with the accompanying drawings. However, embodiments are not limited to embodiments disclosed in the following description but may be embodied in various different forms. The embodiments, which may be described below, may be provided to complete the disclosure and to correctly inform those skilled in the art. Embodiments may be defined only by the scope of the accompanying claims. Throughout the specification, the same components are denoted by the same reference numerals. 
     Embodiments may be described in detail with reference to the accompanying drawings. 
       FIG. 1  is a view schematically showing an air conditioner according to an example embodiment.  FIG. 2  is a view schematically showing an outdoor unit and an indoor unit according to an example embodiment. Other embodiments and configurations may also be provided. 
     As shown in  FIGS. 1 and 2 , an air conditioner may include at least one indoor unit  20  ( 21  to  24 ) and at least one outdoor unit  10  ( 11  and  12 ). Additionally, the air conditioner may include at least one remote controller  30  ( 31  and  32 ) connected to the indoor unit  20  for allowing a user to input a command to the indoor unit  20 . The air conditioner may further include a remote control unit  40  connected to the indoor unit  20  and the outdoor unit  10  for monitoring and controlling operations of the indoor unit  20  and the outdoor unit  10 . 
     Based on the installation type thereof, the air conditioner may be classified as a ceiling mounted type air conditioner, a floor stand type air conditioner, and/or a wall mounted type air conditioner. In addition to the outdoor unit and the indoor unit, the air conditioner may further include a ventilation unit, an air cleaning unit, a humidification unit, a dehumidification unit, and/or a heating unit. 
     The indoor unit  20  may include a discharge port, through which heat-exchanged air is discharged. The discharge port is provided an air direction control unit for opening and closing the discharge port and for controlling a direction of air discharged through the discharge port. The indoor unit  20  may control a rotational speed of an indoor unit fan to control air that is suctioned and air that is discharged and to adjust a flow rate of air. The indoor unit  20  may further include an output unit for displaying an operation state and setting information of the indoor unit  20 , and an input unit for allowing a user to input setting data. 
     The outdoor unit  10  may operate in a cooling mode or a heating mode according to demand of the indoor unit  20 , which is connected to the outdoor unit  10 , or a control command from the remote control unit  40 . Additionally, the outdoor unit  10  may supply a refrigerant to the indoor unit  20 . 
     The outdoor unit  10  may include at least one compressor  2  for compressing a refrigerant introduced into the compressor  2  to discharge a high-pressure gas refrigerant, an accumulator  3  for separating a gas refrigerant and a fluid refrigerant from each other to prevent the fluid refrigerant from being introduced into the compressor  2  in a state in which the fluid refrigerant is not evaporated, an oil separator (not shown) for collecting oil from the refrigerant discharged from the compressor, an outdoor heat exchanger  4  for exchanging heat with outdoor air to condense or evaporate the refrigerant, an outdoor unit fan  5  for introducing air into the outdoor heat exchanger  4  to more smoothly perform heat exchange between the outdoor heat exchanger  4  and the air and discharging the heat-exchanged air outdoors, a four-way valve  7  for changing the flow channel of the refrigerant based on the operation mode of the outdoor unit  10 , an outdoor electronic expansion valve  6  configured to be controlled based on sub-cooling and super-heating in a heating operation, at least one pressure sensor (not shown) for measuring pressure, at least one temperature sensor (not shown) for measuring temperature, and a control device (not shown) for controlling the operation of the outdoor unit and communicating with other units. 
     In a cooling operation (of the air conditioner), the outdoor heat exchanger  4  acts as a condenser for suctioning a gas refrigerant and condensing the suctioned gas refrigerant using outdoor air. On the other hand, in a heating operation (of the air conditioner), the outdoor heat exchanger  4  may act as an evaporator for suctioning a liquid refrigerant and evaporating the suctioned liquid refrigerant using outdoor air. 
     The outdoor unit fan  5  may include an outdoor unit fan motor  5   b  for generating driving force under control of the control device (not shown) of the outdoor unit  10 , and an outdoor fan  5   a  rotated by the driving force from the outdoor unit fan motor  5   b  to generate blowing force. 
     In the cooling operation (of the air conditioner), an indoor heat exchanger  8  acts as an evaporator for suctioning a liquid refrigerant and evaporating the suctioned liquid refrigerant using air in the room in which the indoor unit  20  that has requested the cooling operation is installed, to cool the indoor air. On the other hand, in the heating operation (of the air conditioner), the indoor heat exchanger  8  acts as a condenser for suctioning a gas refrigerant and condensing the suctioned gas refrigerant using air in the room in which the indoor unit  20  that has requested the heating operation is installed, to increase the temperature of the indoor air. 
     An indoor unit fan  9  may include an indoor unit fan motor  9   b  for generating driving force under the control of a control device (not shown) of the indoor unit  20 , and an indoor fan  9   a  connected to the indoor unit fan motor  9   b  such that the indoor fan  9   a  is rotated by the driving force from the indoor unit fan motor  9   b  to generate blowing force. 
     The air conditioner may act as a cooler for cooling the room. Alternatively, the air conditioner may act as a heat pump for cooling or heating the room. 
     The remote control unit  40  may receive data from the indoor unit  20  to display an operation state of the indoor unit, and the remote control unit  40  may transmit input data to the indoor unit  20  to control the indoor unit  20  to operate according to a predetermined setting. Additionally, in a situation in which the indoor unit  20  or the outdoor unit  10  is abnormal, the remote control unit  40  may display, on a screen, an warning corresponding thereto. 
     The remote controller  30  may connect to the indoor unit  20  in a wired or wireless fashion to transmit operation setting data to the indoor unit  20 . The remote controller  30  may allow operation schedules of the indoor unit  20  as well as operation settings (such as modes, temperature, and a flow rate of air) of the indoor unit  20  to be inputted, and the remote controller  30  may transmit the input data to the indoor unit  20  such that the indoor unit  20  can be operated based on the input data. Additionally, the remote controller  30  may receive state information from the indoor unit  20 , and may display the received state information of the indoor unit  20 . 
       FIG. 3  is a block diagram showing a control construction for sensing abnormality of a compressor or a fan motor of the air conditioner according an example embodiment. Other embodiments and configurations may also be provided. 
     Referring to  FIG. 3 , the outdoor unit  10  may include a power supply unit  140  for supplying electric power, an outdoor unit fan  180 , a fan driving unit  170 , a compressor  160 , a compressor driving unit  150 , a data unit  120 , and a control unit  110  (or controller) for controlling overall operation of the outdoor unit  10 . 
     Additionally, the outdoor unit  10  may further include a communication unit for communicating with the indoor unit  20  and the remote control unit  40 . The communication between the outdoor unit  10  and the indoor unit  20  and the communication between the remote control unit  40  and the outdoor unit  10  may be performed using a same communication method or different communication methods in order to transmit data. 
     The outdoor unit  10  may further include an output unit (such as a display) for displaying information about an operation state of the outdoor unit  10 . The control unit  110  of the outdoor unit  10  may transmit data to the indoor unit  20  or the remote control unit  40  such that the data from the outdoor unit  10  can be displayed on a display unit (or display) provided in the indoor unit or a display unit (or display) provided in the remote control unit  40 . 
     The power supply unit  140  may supply electric power necessary to operate the air conditioner from the outside of the air conditioner. The power supply unit  140  may rectify and smooth the electric power input to the power supply unit  140 , and supply the rectified and smoothened electric power to the respective units. Additionally, the power supply unit  140  may include an overcurrent prevention unit for preventing damage to the air conditioner due to the input electric power. 
     Upon receiving operation current supplied from the compressor driving unit  150 , the compressor  160  may compress a refrigerant to discharge a high-temperature, high-pressure gas refrigerant. 
     The compressor driving unit  150  may control the operation of the compressor  160  according to a control command from the control unit  110 . In a situation in which the compressor  160  is an inverter type compressor, the compressor driving unit  150  may control an operation frequency of the compressor  160 . 
     In a situation in which heat exchange between the outdoor heat exchange and the refrigerant is performed, the outdoor unit fan  180  may discharge heat-exchange air from the air conditioner. 
     The fan driving unit  170  may control operation of the outdoor unit fan  180 , and apply operation power to the outdoor unit fan  180 , according to the control command from the control unit  110 . 
     The fan driving unit  170  and the compressor driving unit  150  may each include an inverter. 
     A sensing unit  130  (or sensor) may be installed inside or outside the outdoor unit  10  to sense and measure data about the outdoor unit  10  and data about the state of the outdoor unit  10  during operation of the outdoor unit  10  and to transmit the sensed and measured data to the control unit  110 . 
     The sensing unit  130  may include a plurality of sensors. For example, the sensing unit  130  may include sensors installed inside and outside the outdoor unit  10  for measuring temperature, pressure, humidity, carbon dioxide, flow rate of air, voltage, current and/or etc. 
     The control unit  110  may control the compressor driving unit  150  and the fan driving unit  170  based on the data received from the indoor unit  20  or the remote control unit  40  such that the compressor  160  and the outdoor unit fan  180  can be operated. 
     The control unit  110  may generate a control command to vary operations of the compressor  160  and the outdoor unit fan  180  based on the data input from the sensing unit  130 , and apply the generated control command to the compressor driving unit  150  and the fan driving unit  170 . 
     The control unit  110  (or controller) may determine whether the compressor  160  and the outdoor unit fan  180  are abnormal based on the data received from the sensing unit  130 , and may control a warning corresponding thereto to be output. 
     More particularly, in a situation in which the compressor  160  and the outdoor unit fan  180  are abnormal, with a result that the compressor  160  and the outdoor unit fan  180  cannot operate any longer, the control unit  110  may control operation of the air conditioner to be stopped, and control a warning corresponding thereto to be output. 
     On the other hand, in a situation in which it is determined (based on the data received from the sensing unit  130 ) that the compressor  160  and the outdoor unit fan  180  are abnormal; however, the compressor  160  and the outdoor unit fan  180  can be operated, the control unit  110  controls operation of the air conditioner to be continuously performed, and controls a warning corresponding thereto to be output. 
     As previously described, the compressor  160  or the outdoor unit fan  180  may be provided with a motor, by driving of which the compressor  160  or the outdoor unit fan  180  is operated. In the following description, motors are provided in the compressor, the outdoor unit fan, and the indoor unit fan. 
     The above description was based on the outdoor unit  10 . However, the same description may equally apply to the indoor unit  20 . In a situation in which the indoor unit fan is abnormal, abnormality of the indoor unit fan may be sensed, and a warning corresponding thereto may be output. 
     As shown in  FIG. 4 , a motor  50  may operate by a driving control unit  60  for controlling the driving of the motor  50 . 
     As shown in  FIG. 4 , the driving control unit  60  may include a motor control unit  61  for generating a control signal to drive the motor  50 , and a motor driving unit  62  for applying operation current to the motor  50  according to the control signal. 
     Construction of the driving control unit  60  may equally apply to the compressor driving unit  150  and the fan driving unit  170 . 
     The sensing unit  130  may include a first sensor  131  for sensing operation current applied from the motor driving unit  62  to the motor  50  and a signal processing unit  139  for analyzing data received from the sensor to sense abnormality. 
     The sensing unit  130  may further includes a second sensor for sensing the motor driving unit  62 . 
     The signal processing unit  139  may determine a state and abnormality of the motor  50  based on data sensed by the first sensor  131 . Additionally, the signal processing unit  139  may determine progress of a breakdown and a breakdown portion of the motor  50  based on a sensed current waveform. 
     Since breakdown of the motor  50  does not occur at one time but occurs as a result of accumulation of problems, the sensing unit  130  senses the state of the motor  50  at the breakdown progress step in order to sense abnormality that may subsequently occur. 
     For example, when a bearing of the motor is excessively worn, gap eccentricity may be caused, with a result that a magnetomotive force waveform of the motor may change. 
     In a situation in which the current waveform received from the first sensor  131  changes, the signal processing unit  139  may determine a state of the motor based thereon. 
     Additionally, in a situation in which a stator of the motor is abnormal, mechanical vibration may be generated from the motor, with a result that a specific current frequency of the stator is generated. When the operation current is sensed by the first sensor  131 , the current frequency generated from the motor may also be sensed. 
     In a situation in which such a current frequency is included in the operation current sensed by the first sensor  131 , the signal processing unit  139  may determine that the stator is abnormal, and may transmit data about a breakdown position to the control unit  110 . 
     In a situation in which the current waveform of the operation current sensed by the first sensor  131  has changed, the signal processing unit  139  may determine that the bearing is abnormal, and may transmit data about the breakdown position to the control unit  110 . 
     The sensing unit  130  may further include an additional communication module and a memory. 
     The signal processing unit  139  may transmit data to the control unit  110  through the communication module in a wireless communication fashion. Alternatively, the signal processing unit  130  may be connected to the outdoor unit or the indoor unit via a communication cable to transmit data to the control unit  110 . 
     The control unit  110  (or controller) may operate based on data received from the sensing unit  130 . In a situation in which the motor is abnormal with the result that the motor cannot operate, the control unit controls the motor to not operate. On the other hand, in a situation in which the motor is abnormal but the motor can operate, the control unit controls a warning corresponding thereto to be output. In a situation in which no display unit is provided at the outdoor unit, the control unit  110  may transmit the data to the remote control unit or the indoor unit such that the warning can be displayed on the remote control unit side or the indoor unit side. Additionally, in a situation in which the indoor unit is a ceiling mounted type indoor unit, the indoor unit may transmit the data to the remote control unit or the remote controller such that the warning can be displayed on the remote control unit side or the remote controller side. 
       FIG. 5  is a view showing an installation example of a sensing unit of an air conditioner according to an example embodiment. Other embodiments and configurations may also be provided. 
     As shown in  FIG. 5 , the sensing unit  130  may be installed on a power cable that is connected to the compressor, the indoor unit, or the indoor unit fan. 
     The sensing unit  130  may be detachably attached to the power cable. The sensing unit  130  may be configured to surround the power cable. 
     For example, the sensing unit  130  may be configured to have a clip shape such that the sensing unit  130  can be mounted on the power cable, which is connected to the motor. 
     Alternatively, the sensing unit  130  may be mounted on the power cable in a state in which the sensing unit  130  is not directly connected to the power cable. That is, the sensing unit  130  may be disposed at the power cable in a state in which the sensing unit  130  is spaced apart from the power cable by a predetermined distance. 
     The first sensor  131  may be mounted on one of the three-phase power lines connected from the motor driving unit  62  to the motor  50  to sense operation current flowing along the power cable in a non-contact fashion. The first sensor  131  may sense current using an induced current. 
     The signal processing unit  139  may analyze the sensed current, and transmit data about the state of the motor to the control unit  110  (or controller). 
     The control unit  110  may determine whether to continuously operate the motor based on the data received from the signal processing unit  139 , and control a warning corresponding thereto to be output. 
     Upon determining (based on the received data) that the motor has broken down, and the predetermined operation of the motor cannot be performed, the control unit  110  may control operation of the motor to stop, and control an error related thereto to be output. 
     Upon determining, based on the received data, that the motor is abnormal but the motor can operate, the controller  110  controls operation of the air conditioner to be continuously performed, and controls an warning corresponding thereto to be output such that the user can check the state of the motor. 
     Based on the state of the motor (e.g. whether the motor has broken down or the motor is abnormal but has not yet broken down), the controller  110  controls different warnings to be output such that the user can check the state of the motor. 
       FIG. 6  is a view showing an example of a warning output from an air conditioner according to an example embodiment. Other embodiments and configurations may also be provided. 
     As shown in  FIG. 6 , an warning about abnormality of the compressor or the outdoor unit fan (of the outdoor unit) or the indoor unit fan (of the indoor unit) may be output through the remote control unit  40 . As previously described, the warning may also be output through the display unit (or display) of the indoor unit or the remote controller. 
     In a situation in which one selected from among the compressor  160  (or  2 ), the outdoor unit fan  180  (or  5 ), and the indoor unit fan  9  is abnormal, the sensing unit  130  may sense the abnormality and transmit data about the abnormality to the control unit  110 . The control unit  110  may control operation of the air conditioner based on the data about the abnormality, and control a warning corresponding thereto to be output. 
     As shown in  FIG. 6( a ) , a warning message  51  may be displayed on a display unit (or display) in the form of a popup window. 
     Upon determining that the operation of the air conditioner cannot be continuously performed any longer based on data about the abnormality sensed by the sensing unit  130 , the controller  110  may control the operation of the air conditioner to be stopped, and control an output of a warning message about the breakdown and the stop of the air conditioner. 
     A help button for displaying an additional description of the breakdown and a help message may be further displayed on the screen. 
     As shown in  FIG. 6( b ) , abnormality of one selected from among the units (i.e., the outdoor unit and the indoor unit) may be displayed on the remote control unit  40  such that an icon  52  of the corresponding unit is distinguished from icons of other units, and a warning message  53  corresponding thereto is also displayed on the remote control unit  40 . 
     As shown in  FIG. 6( c ) , an abnormal unit  54  may be displayed such that the abnormal unit  54  is distinguished from the other units. In a situation in which the abnormality is not related to operation of the air conditioner or in a situation in which the abnormality is not serious to such an extent that it is necessary to stop operation of the air conditioner, however, the operation of the air conditioner may be continuously performed. As a result, operation information  56  may then be displayed on the screen, and a warning message  55  about the generated abnormality may be displayed on a portion of the screen. 
     In the air conditioner, a breakdown that has occurred may be sensed and the breakdown position may be specified, and progress of a breakdown that will occur in advance may be sensed and preparations may be made for the breakdown of the air conditioner. 
     Although all components constituting an embodiment have been described to be combined into a single unit and be operated as the single unit, embodiments are not limited to such an embodiment. Depending upon embodiments, all the components may be selectively combined into one or more units and operated as one or more units within the scope of the object of the present invention. 
     As is apparent from the above description, in the air conditioner, the state of the motor may be sensed using a non-contact type sensor, whereby it is possible to easily monitor states of the compressor and the fan, to sense progress of the abnormality of the compressor and the fan or whether the compressor and the fan have broken down, and to estimate the expected lifespan of the compressor or the fan based on the state thereof using the monitored results. Damage to the air conditioner may be prevented due to abnormality of the compressor or the fan motor. 
     It is an object to provide an air conditioner that is capable of monitoring an operation state of a compressor in the air conditioner and diagnosing the progress of a breakdown of a compressor and a fan or a breakdown portion. 
     Objects can be accomplished by the provision of an air conditioner including a display unit (or display) for displaying the operation state of the air conditioner, a motor configured to rotate to generate a driving force, a driving control unit for controlling driving of the motor, a sensing unit for sensing abnormality of the motor, and a control unit for controlling operation of the air conditioner based on data received from the sensing unit, wherein the sensing unit is mounted on a power cable, in which operation current supplied from the driving control unit to the motor flows, for sensing the operation current to sense a breakdown and an operation state of the motor, and the display unit outputs the operation state of the motor in response to a control command from the control unit and outputs a warning message about the abnormality generated in the motor. 
     Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to affect such feature, structure, or characteristic in connection with other ones of the embodiments. 
     Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.