Patent Publication Number: US-8973385-B2

Title: Refrigeration system

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/892,715, having a filing date of Mar. 2, 2007, and titled “Refrigeration System,” the complete disclosure of which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     The present disclosure relates generally to a refrigeration system for use in a refrigeration device (e.g. temperature controlled case, refrigerated storage unit, merchandiser, cooler, etc.). The present disclosure relates more particularly to a refrigeration system that is suitable for use with refrigeration devices configured to operate between a first cooling mode (e.g., low temperature cooling mode, etc.) and a second cooling mode (e.g., medium temperature cooling mode, etc.). The present disclosure relates more particularly to a control module of the refrigeration system and a method of controlling temperature within the refrigeration device depending for various cooling modes. 
     It is generally known to provide refrigeration devices (e.g., temperature controlled cases, refrigerated storage units, merchandisers, coolers, etc.) having a refrigeration system for circulating a refrigerant or coolant through one or more cooling elements within the device to maintain items (such as food products and the like) within a certain desirable temperature range. The desirable temperature range will vary depending on the type of items that are received by the refrigeration device. Refrigeration devices are often distinguished by those skilled in the art of commercial refrigeration as being either a “low temperature” refrigeration device or a “medium temperature” refrigeration device. Low temperature refrigeration devices are generally used to display or otherwise support items including, but not limited to, frozen food products or partially frozen food products. Medium temperature refrigeration devices are generally used to display or otherwise support items including, but not limited to, fresh food products. 
     To maintain items within the refrigeration device at the desirable temperature range, refrigeration systems typically include a control module configured to regulate the positioning of a throttle device to modulate the flow of refrigerant that is supplied to the cooling elements. Based upon signals received from various sensing devices, the control module compares a value representative of an actual reading within the refrigeration device with a predetermined reference value and regulates the positioning of the throttle device accordingly to modulate the flow of refrigerant. 
     In conventional control modules, only a single predetermined reference value for regulating the position of a throttle device may be inputted by a user and/or manufacturer (e.g., either a predetermined reference value for a low temperature refrigeration device or a predetermined reference value for a medium temperature refrigeration device, etc.). Since the predetermined reference value is different for a low temperature refrigeration device and a medium temperature refrigeration device, a different control module is required for each application. 
     For certain applications, it may be desirable to change the cooling mode at which the refrigeration device is operating (e.g., convert a low temperature refrigeration device to a medium temperature refrigeration device, convert a medium temperature refrigeration device to a low temperature refrigeration device, etc.). If the refrigeration device is equipped with a conventional control module, the user must add and/or replace a control module in order to complete the conversion process. Adding and/or replacing a control module may increase the expense and/or time required to convert the refrigeration device between a refrigeration device configured to operate at a different cooling mode. 
     Accordingly, it would be desirable to provide a refrigeration system that can operate between a first cooling mode (e.g., a low temperature cooling mode, etc.) and a second cooling mode (e.g., a medium temperature cooling mode, etc.) without requiring a separate control module for each cooling mode. It would also be desirable to provide a refrigeration system having a control module that is configured to determine whether the refrigeration system is operating within a first cooling mode and a second cooling mode. It would be further desirable to provide a refrigeration system having a control module that is configured to determine whether the refrigeration system is operating within a first cooling mode and a second cooling mode without requiring any manipulation by a user. It would be further desirable to provide a refrigeration system having a control module that modulates the flow of refrigerant through a cooling element. It would be further desirable to provide a refrigeration system that regulates a throttle device (such as a superheat valve) to modulate the flow of refrigerant during the cooling mode. It would also be desirable to provide a refrigeration system having a control module capable of applying a first predetermined setpoint for regulating the throttle device in the first cooling mode and applying a second predetermined setpoint for regulating the throttle device in the second cooling mode. 
     Accordingly, it would be desirable to provide a refrigeration system for a temperature controlled case having any one or more of these or other desirable features. 
     SUMMARY 
     According to one embodiment a temperature controlled case includes an enclosure defining an airspace for receiving products therein, a refrigeration system configured to circulate a refrigerant through an expansion device and at least one cooling element to cool the airspace and a control module having a first predetermined setpoint corresponding to a first cooling mode and a second predetermined setpoint corresponding to a second cooling mode. The control module is configured to determine which one of the first cooling mode and the second cooling mode the refrigeration system is to operate within and to apply the corresponding predetermined setpoint for reference in modulating a position of the expansion device. 
     According to another embodiment a refrigeration system for a temperature controlled storage unit includes a supply line and a return line coupled to a cooling element and configured to circulate a refrigerant through the cooling element to provide cooling to a space for receiving products. The refrigeration system also includes a control module configured to maintain at least a first cooling mode and a second cooling mode. The control module has a predetermined setpoint temperature. The control module is configured to obtain a saturation temperature of the refrigerant and compare the saturation temperature to the predetermined setpoint temperature to determine which one of the first cooling mode and the second cooling mode the refrigeration system is to operate within. 
     According to another embodiment, a method of controlling a temperature controlled case includes providing an enclosure having a space configured to receive products to be cooled and providing a cooling element configured to receive a refrigerant to cool the space. The method also includes providing a control module with a predetermined temperature setpoint used for determining whether the case is to operate within a first cooling mode or a second cooling mode, a first predetermined superheat setpoint corresponding to the first cooling mode, a second predetermined superheat setpoint corresponding to the second cooling mode, and signals representative of at least one of a refrigerant pressure and a refrigerant temperature. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic image of a side elevation view of a temperature controlled case according to an exemplary embodiment. 
         FIGS. 2A-2D  are schematic images of a block diagram of a refrigeration system for a temperature controlled case according to exemplary embodiments. 
         FIG. 3  is a flow chart illustrating a method of controlling the refrigeration system of  FIGS. 2A and 2C . 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to the FIGURES, a refrigeration system for use in a refrigeration device such as a temperature controlled case is shown according to one embodiment. The refrigeration system is shown to have a compressor, condenser, expansion device, one or more cooling elements (e.g., coils, finned-coils, heat exchangers, flow-through pans, etc.), and suitable sensors for circulating a fluid (such as a refrigerant or coolant) through the cooling element to maintain the temperature of products, such as food products within a storage area of the case, at a relatively constant storage temperature. The refrigeration system is further shown as having a control module that interfaces with suitable components of the temperature controlled case and the refrigeration system to enable the temperature controlled case to achieve a desired temperature range and maintain the storage area of the case within such temperature range. 
     The control module is capable of determining (e.g., recognizing, calculating, etc.) whether the case was intended for operating within a first cooling mode (e.g., a “low temperature cooling mode,” etc.) or a second cooling mode (e.g., a “medium temperature cooling mode,” etc.). For purposes of this disclosure, the phrase “low temperature cooling mode” is used broadly to refer to applications wherein the storage area of the case is used for displaying frozen or partially frozen products. For example, a low temperature cooling mode may be used to maintain the storage area of the case between approximately negative (−) 15 degrees Fahrenheit (F) and appropriately 15 degrees F., and may include cases operating at a variety of “low” temperatures (e.g., less than approximately 28 degrees F., etc.) for various product storage requirements. A low temperature cooling mode may be used for storing and/or displaying ice cream and/or frozen food products such as frozen vegetables, and/or frozen prepared foods. For purposes of this disclosure, “medium temperature cooling mode” is used broadly to refer to applications wherein the storage area of the case is warmer than the low temperature cooling mode. For example, a medium temperature cooling mode may be used to maintain the storage area of the case between approximately 20 degrees F. and approximately 50 degrees F. A medium temperature cooling mode may be used for storing and/or displaying fresh food products such as milk and other dairy products, fish, meats, and/or produce. 
     The control module determines whether the case is intended for operating within a first cooling mode or a second cooling mode by comparing an actual reading within the case (e.g., the actual temperature of the refrigerant at the exit (or suction side) of the cooling elements, etc.) (T act) to a predetermined reference range or setpoint (e.g., a temperature range or setpoint, etc.) programmed or otherwise stored within the control module (T ref). If T act is less than T ref, the control module “knows” or is configured to determine that the case is intended to operate within the first cooling mode (e.g., a low temperature cooling mode, etc.). According to an exemplary embodiment, if T act is greater than T ref, the control module “knows” or is configured to determine that the case is intended for operating within the second cooling mode (e.g., a medium temperature cooling mode, etc.). 
     Programmed or otherwise stored within the control module is a separate predetermined range or setpoint (used for modulating the flow of refrigerant) for both the first cooling mode and the second cooling mode. Once the control module determines whether the case is intended to operate within a first cooling mode or a second cooling mode, the control module applies the predetermined range or setpoint (e.g., a predetermined superheat temperature range or setpoint, etc.) corresponding to the particular cooling mode for modulating the flow of refrigerant. During operation, the control module references this predetermined setpoint in an attempt to maintain the storage area of the case within the desired temperature range. The control module compares this predetermined setpoint to an actual reading within the case (e.g., the actual superheat temperature of the refrigerant, etc.) and maintains the desired temperature range for the case by using the expansion device (e.g., a throttling device such as a superheat valve) to increase or limit the amount of refrigerant being supplied to the cooling element. According to an exemplary embodiment, if the actual reading is greater than the predetermined setpoint, the control module may regulate the expansion device in a way that supplies more refrigerant to the cooling element. 
     Further, if the control module determines that the case has changed from a case intended to operate within the first cooling mode to a case intended to operate within the second cooling mode (or vice versa), the control module changes the predetermined setpoint for modulating the flow of refrigerant accordingly. The control module is able to change this predetermined setpoint without requiring additional manipulation by a user since a suitable predetermined setpoint is programmed or otherwise stored within the control module for each possible cooling mode. By providing a control module that is capable determining the intended cooling mode of the case, and changing the predetermined setpoint for modulating the flow of refrigerant accordingly without additional manipulation by a user, the refrigeration system is intended to simplify the conversion process and eliminate the need to add and/or replace the control module in the event that a case is intended to change between cooling modes. 
     Referring to  FIG. 1 , a refrigeration system for a refrigeration device shown schematically as a temperature controlled case  10  is shown according to an exemplary embodiment. The case  10  is shown as a rear-access, service-type case, but may be any suitable enclosure for maintaining a temperature controlled environment for the storage of objects such as food products and the like (such as open front or open top cases, closed door cases, etc.). The case is shown to include a product support surface  12  within an airspace  14  for storage of products  16 , and cooling element(s)  40  configured to cool air circulated with the airspace  14  by a fan  18 . According to various alternative embodiments, the cooling element(s) may be positioned at any suitable location within the airspace and the air may be circulated by any type of forced or natural circulation. 
     The case  10  is capable of operating between a first cooling mode (e.g., a first cooling load application, etc.) and a second cooling mode (e.g., a second cooling load application, etc.). According to an exemplary embodiment, the first cooling mode is a low temperature cooling mode, while the second cooling mode is a medium temperature cooling mode. According to various alternative embodiments, the case may be configured to operate at only one of a first cooling mode and a second cooling mode. According to further alternative embodiments, the case may be configured to operate at or between cooling modes having temperatures outside of one or more of the temperature ranges provided above for the low temperature cooling mode and a the medium temperature cooling mode. 
     The case  10  may also include a defrost system intended to minimize or generally eliminate the accumulation of frost and/or ice on the surfaces of the cooling element(s)  40 . According to an exemplary embodiment, the case  10  may include a defrost system such as that disclosed in U.S. Pat. No. 7,275,376, titled “Defrost System for a Refrigeration Device” filed Apr. 28, 2005, the disclosure of which is hereby incorporated by reference in its entirety. 
     Referring to  FIGS. 1-2D , a refrigerant system  20  circulates a refrigerant through a closed loop system shown to include a compressor  22  for compressing a refrigerant vapor, a condenser  24  for cooling and condensing the compressed refrigerant vapor, an expansion metering device (e.g. throttle valve, electronic expansion valve, etc. shown as a superheat valve  26 ) for “expanding” the liquid refrigerant to a low-temperature saturated liquid-vapor mixture for use in cooling element(s)  40  for cooling airspace  14  and products  16  within the case  10 . According to an exemplary embodiment, the refrigerant is any commercially available refrigerant, but may be any suitable refrigerant for use with a refrigeration device. The refrigeration system  20  may be self-contained within the case (as shown schematically in  FIGS. 2C and 2D ) or a portion of the refrigeration system may be located remotely from the case (as shown schematically in FIGS.  1  and  2 A- 2 B). 
     According to one embodiment, the refrigerant flows through a refrigerant supply line  28  (e.g. “liquid line” etc.) to the superheat valve  26  at a first flow rate and is expanded by the superheat valve  26  to form a liquid-vapor mixture at a “saturation temperature” within the cooling element(s)  40  to maintain the temperature of the food products  16  at a desired storage or display temperature, consistent with store or industry food safety codes or guidelines. 
     As the saturated liquid-vapor mixture of refrigerant progresses through the cooling element(s)  40  and absorbs heat from the air circulated from the airspace  14 , the vapor percentage of the liquid-vapor mixture increases, and usually becomes completely vaporized. When the refrigerant is completely vaporized within a portion of the cooling element(s)  40  (e.g. usually at or near an outlet portion of the cooling element, such as the last one or several tube passes of a coil), the refrigerant temperature increases above the refrigerant&#39;s saturation temperature as the refrigerant continues to circulate through the cooling element(s)  40 . The amount of temperature increase above the saturation temperature is referred to herein as the “superheat temperature.” 
     Referring further to  FIGS. 2A-2D , the refrigeration system is further shown as comprising a control module  50 . The function of control module  50  is at least two-fold. First, the control module  50  is configured to determine whether the case  10  is intended for operating within the low temperature cooling mode or the medium temperature cooling mode. Second, with the intended cooling mode determined (and a corresponding predetermined superheat temperature setpoint established), the control module  50  is configured to modulate the position of the superheat valve  26  to maintain the superheat temperature of the refrigerant within a desired temperature range. 
     Control module  50  includes a suitable computing device (such as a microprocessor or programmable logic controller  52 ) configured to receive signals representative of temperature and/or pressure from the components of the case  10  and to provide output signals for controlling the position of the superheat valve  26  to achieve the desired superheat temperature of the refrigerant for the particular cooling mode and to maintain the superheat temperature of the refrigerant within a desired range for that particular cooling mode. 
     Referring to  FIGS. 2A and 2C , a temperature/pressure sensing arrangement is shown to include a temperature sensor  32  and a pressure sensor  34  provided on a refrigerant return line  30  (e.g. “suction” line, etc.) adjacent to the exit of the cooling element(s)  40 . The pressure sensor  34  provides a signal representative of refrigerant pressure to the control module  50 , which calculates a corresponding saturation temperature (T sat) of the refrigerant at the exit of the cooling element(s)  40 , for example, by using a thermodynamic properties look-up table for the particular type of refrigerant being used in the refrigeration system. The temperature sensor  32  provides a signal representative of actual temperature of the refrigerant at the exit of the cooling element(s)  40  (T exit). According to an exemplary embodiment, the temperature sensor  32  is a commercially available thermistor (but could be a thermocouple or RTD of the like) and the pressure sensor  34  is a commercially available pressure transducer. According to various alternative embodiments, the temperature sensor and the pressure sensor may be any other suitable sensor. 
     The control module  50  determines whether the case  10  is intended for operating within the low temperature cooling mode or the medium temperature cooling mode by comparing T sat to a predetermined setpoint stored within the control module  50  (T ref). T ref may be set at any suitable temperature. According to an exemplary embodiment, if T sat is less than T ref, the control module  50  knows that the case  10  is intended to operate within the low temperature cooling mode. For such an embodiment, if T sat is greater than T ref, the control module  50  knows that the case  10  is intended to operate within the medium temperature cooling mode. According to various alternative embodiments, the value of T ref may vary depending upon the different cooling modes. 
     Programmed or otherwise stored within the control module  50  is a separate predetermined desired range or setpoint for the superheat temperature for both the low temperature cooling mode and the medium temperature cooling mode. Once the control module  50  determines whether the case  10  is intended for operating within the low temperature cooling mode or the medium temperature cooling mode, the control module  50  applies the predetermined setpoint for the superheat temperature corresponding to the intended cooling mode when controlling the temperature of the case. 
     The control module  50  uses the predetermined superheat temperature setpoint as a reference when controlling the position of the superheat valve  26 . During the low temperature cooling mode and the medium temperature cooling mode, the superheat valve  26  is configured to modulate a flow rate of the refrigerant corresponding to the duty or demand experienced by the case  10 . The flow rate may be increased during high demand and the flow rate may be decreased during low demand, so that the temperature of refrigerant in the cooling element(s)  40  maintains the storage area within the desired temperature ranges. 
     Still referring to  FIGS. 2A and 2C , the temperature/pressure sensing arrangement of the control module  50  is configured to provide output signals for controlling the position of the superheat valve  26  to maintain the superheat temperature of the refrigerant within a desired range for both the low temperature cooling mode and the medium temperature cooling mode. The control module  50  calculates the difference between T exit and T sat to determine the actual superheat temperature of the refrigerant. The control module  50  compares the actual superheat temperature of the refrigerant to the relevant predetermined setpoint for the superheat temperature and sends an output signal to modulate the position of the superheat valve  26  to attain or maintain the desired superheat temperature at the exit of the cooling element(s)  40 . 
     The saturation temperature of the refrigerant for the medium temperature cooling mode is typically within a range of approximately 17-32 degrees F., and more particularly within a range of 22-29 degrees F. The saturation temperature of the refrigerant is intended to maintain at least a portion of the cooling element(s)  40  at a temperature corresponding approximately to the refrigerant&#39;s saturation temperature during the respective cooling mode. 
     Referring to  FIGS. 2B and 2D , a temperature/temperature sensing arrangement is shown to include a first temperature sensor  36  located at an inlet area of the cooling element(s) (e.g. on a first pass of a coil  42  of a cooling element, etc.) and a second temperature sensor  32  located adjacent to the exit of the cooling element(s)  40 . The first temperature sensor  36  is intended to provide a signal that is reasonably representative of the saturation temperature (T sat) of the refrigerant to the control module  50 . The second temperature sensor  32  is intended to provide a signal representative of the actual temperature of the refrigerant at the exit of the cooling element(s)  40  (T exit). 
     Similar to the exemplary embodiment detailed above, the control module  50  determines whether the case  10  is intended for operating within the low temperature cooling or the medium temperature cooling mode by comparing T sat to a predetermined setpoint programmed or otherwise stored within the control module  50  (T ref). However, unlike the exemplary embodiment detailed above, the control module  50  does not have to calculate T sat, but instead receives a signal from the first temperature sensor reasonably representative of T sat. 
     Once the control module  50  determines whether the case  10  is intended to operate within the low temperature cooling mode or the medium temperature cooling mode, the control module  50  applies the appropriate predetermined setpoint for the superheat temperature to control the temperature of the case  10 . The control module  50  calculates the difference between T exit and T sat to determine the actual superheat temperature of the refrigerant. The control module  50  compares the actual superheat temperature of the refrigerant to the selected predetermined desired setpoint for the superheat temperature and sends an output signal to modulate the position of the superheat valve to attain or maintain the desired superheat temperature at the exit of the cooling element. According to alternative embodiments, the temperature and/or pressure sensors may be provided at any suitable location and on any suitable component to provide signals sufficient to control the superheat temperature of the refrigerant as the refrigerant passes through the cooling element. 
     Referring to  FIG. 3 , a method of controlling a refrigeration system is shown according to an exemplary embodiment. The method includes providing an enclosure having a space configured to receive products to be cooled and providing a refrigeration system with a compressor, a condenser, an expansion device, such as a superheat control valve (SCV), one or more cooling elements, suitable sensors for circulating a refrigerant through the cooling element to maintain the temperature of products at a relatively constant storage temperature, and a control module. According to the embodiment illustrated, the refrigeration system includes a pressure transducer or sensor and a temperature sensor provided at a refrigerant return or suction line. The pressure sensor provides a signal representative of refrigerant pressure to the control module (P exit), while the temperature sensor provides a signal representative of actual temperature of the refrigerant at the exit of the cooling elements (T exit). 
     The method also includes providing the control module with a predetermined temperature setpoint (T ref) used for determining whether the case is to operate within a first cooling mode (e.g., a low temperature cooling mode, etc.) or a second cooling mode (e.g., a medium temperature cooling mode, etc.), a first predetermined superheat setpoint corresponding to the first cooling mode, a second predetermined superheat setpoint corresponding to the second cooling mode. According to an exemplary embodiment, the control module calculates a saturated suction temperature (T sat) based on P exit, T exit, and/or the properties or parameters of the refrigerant. The method further includes programming the control module to determine which cooling mode the refrigeration system is to operate by comparing T sat to T ref. The method further includes programming the control module to use the first predetermined superheat setpoint if T sat is less than T ref and to use the second predetermined superheat setpoint if T sat is greater than T ref. 
     The method further includes programming the control module to calculate the actual superheat temperature of the refrigerant and to compare the actual superheat temperature of the refrigerant to either the first predetermined superheat setpoint or the second predetermined superheat setpoint (depending on whether the control module determined that the refrigeration system is to operate within the first cooling mode or the second cooling mode). The method further includes regulating the position of the superheat control valve based on the comparison of the actual superheat temperature to the appropriate predetermined superheat setpoint for modulating the flow of refrigerant to the cooling element. 
     It is also important to note that the construction and arrangement of the elements of the refrigeration system for a temperature controlled case as shown schematically in the embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in the ranges of the different cooling modes for a low temperature cooling mode and a medium temperature cooling mode, variations in superheat temperature during the different cooling modes, values of parameters, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. 
     It should also be noted that suitable sensors may be provided within the case or integrally (or otherwise operably coupled) with the cooling elements(s) to provide input to the refrigeration control system. For example, one or more temperature sensing devices (e.g. thermocouples, RTDs, etc.) may be provided at suitable location(s) within, or on the top side or underside of shelves or other product support surfaces to provide a signal representative of temperature of the product support surface and/or food products to the refrigeration control system. The control module may include a processor such as a microprocessor, programmable logic controller or the like for receiving and monitoring input signals, sending output signals, permitting change or adjustment of setpoints, providing appropriate indications (e.g. alarms, status, temperature, fluid flow rates, mode of operation (such as a first cooling mode or a second cooling mode), etc.) and to interface with local or remote monitoring equipment or stations. The control module may also be configured to initiate a conversion between different cooling modes in any suitable manner. Further, an evaporator pressure regulating (EPR) valve can be added to a low temperature case to convert the case to a medium temperature case. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions. 
     The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions as expressed in the appended claims.