Source: https://patents.google.com/patent/US9541907B2/en
Timestamp: 2019-04-20 06:37:18+00:00

Document:
2008-12-22 Assigned to EMERSON CLIMATE TECHNOLOGIES, INC. reassignment EMERSON CLIMATE TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MCSWEENEY, DANIEL L.
A system and method for calibrating parameters for a refrigeration system having a variable speed compressor is provided. A compressor is connected to a condenser and an evaporator. A condenser sensor outputs a condenser signal corresponding to at least one of a sensed condenser pressure and a sensed condenser temperature. An inverter drive modulates a frequency of electric power delivered to the compressor to modulate a speed of the compressor. A control module is connected to the inverter drive and determines a measured condenser temperature based on the condenser signal, monitors electric power data and compressor speed data from the inverter drive, calculates a derived condenser temperature based on the electric power data, the compressor speed data, and compressor map data for the compressor, compares the measured condenser temperature with the derived condenser temperature, and updates the compressor map data based on the comparison.
This application claims the benefit of U.S. Provisional Application No. 60/978,292, filed on Oct. 8, 2007. The application also claims the benefit of U.S. Provisional Application No. 60/978,258, filed on Oct. 8, 2007. The entire disclosures of each of the above applications are incorporated herein by reference.
The present disclosure relates to compressors and more particularly to a system and method for calibrating parameters of a refrigeration system with a variable speed compressor.
A system is provided comprising a compressor connected to a condenser and an evaporator, a condenser sensor that outputs a condenser signal corresponding to at least one of a sensed condenser pressure and a sensed condenser temperature, an inverter drive that modulates a frequency of electric power delivered to the compressor to modulate a speed of the compressor, and a control module connected to the inverter drive. The control module that determines a measured condenser temperature based on the condenser signal, monitors electric power data and compressor speed data from the inverter drive, calculates a derived condenser temperature based on the electric power data, the compressor speed data, and compressor map data for the compressor, compares the measured condenser temperature with the derived condenser temperature, and selectively updates the compressor map data based on the comparison.
In other features, the control module may calculate a difference between the derived condenser temperature and the calculated condenser temperature, compare the difference with a predetermined threshold, and select one of the derived condenser temperature and the calculated condenser temperature as being more accurate when the difference is greater than the predetermined threshold.
In other features, the control module may generate an alarm when the difference is greater than the predetermined threshold.
A method is provided and includes receiving a condenser signal corresponding to at least one of a condenser pressure and a condenser temperature of a condenser connected to a compressor and an evaporator, modulating a speed of the compressor with an inverter drive configured to modulate a frequency of electric power delivered to the compressor, receiving electric power data and compressor speed data from the inverter drive, calculating a derived condenser temperature based on the electric power data, the compressor speed data, and compressor map data associated with the compressor, determining a measured condenser temperature based on the condenser signal, comparing the derived condenser temperature with the measured condenser temperature, and selectively updating the compressor map data based on the comparing.
In other features, the method may include calculating a difference between the derived condenser temperature and the calculated condenser temperature, comparing the difference with a predetermined threshold, and selecting one of the derived condenser temperature and the calculated condenser temperature as being more accurate when the difference is greater than the predetermined threshold.
In other features, the method may include generating an alarm when the difference is greater than the predetermined threshold.
Another system is provided and comprises a compressor connected to a condenser and an evaporator, an evaporator sensor that outputs an evaporator signal corresponding to at least one of a sensed evaporator pressure and a sensed evaporator temperature, a discharge temperature sensor that outputs a discharge temperature signal corresponding to a temperature of refrigerant exiting the compressor, an inverter drive that modulates a frequency of electric power delivered to the compressor to modulate a speed of the compressor, and a control module connected to the inverter drive. The control module may determine a measured evaporator temperature based on the evaporator signal, monitor electric power data and compressor speed data from the inverter drive, calculate a derived evaporator temperature based on the electric power data, the compressor speed data, the discharge temperature signal, and compressor map data for the compressor, compare the measured condenser temperature with the derived condenser temperature, and selectively update said compressor map data based on the comparison.
In other features, the control module may calculate a difference between the derived evaporator temperature and the calculated evaporator temperature, compare the difference with a predetermined threshold, and select one of the derived evaporator temperature and the calculated evaporator temperature as being more accurate when the difference is greater than the predetermined threshold.
FIG. 2 is a flow chart illustrating an algorithm to calibrate condenser temperature.
FIG. 3 is a schematic view of a refrigeration system.
FIG. 4 is a flow chart illustrating an algorithm to calibrate evaporator temperature.
FIG. 5 is a graph showing discharge super heat correlated with suction super heat and outdoor temperature.
FIG. 6 is a graph showing condenser temperature correlated with compressor power and compressor speed.
FIG. 7 is a flow chart showing derived data for a refrigeration system.
SSH and DSH may be correlated as shown in FIG. 5. The correlation between DSH and SSH may be particularly accurate for scroll type compressors, with outside ambient temperature being only a secondary effect. As shown in FIG. 5, correlations between DSH and SSH are shown for outdoor temperatures (ODT) of one-hundred fifteen degrees Fahrenheit, ninety-five degrees Fahrenheit, seventy-five degrees Fahrenheit, and fifty-five degrees Fahrenheit. The correlation shown in FIG. 5 is an example only and specific correlations for specific compressors may vary by compressor type, model, capacity, etc.
In FIG. 5, typical SSH temperatures for exemplar refrigerant charge levels are shown. For example, as the percentage of refrigerant charge in refrigeration system 5 decreases, SSH typically increases.
As further described in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference, Tcond may be a function of compressor power and compressor speed. Control module 25 may derive Tcond based on compressor power or current and compressor speed. As further described in the disclosure, control module 25 may use Tcond to derive other parameters including compressor capacity, power, energy efficiency ratio, load, Kwh/Day, etc.
A graphical correlation between compressor power in watts and compressor speed is shown in FIG. 6. As shown, Tcond is a function of compressor power and compressor speed. In this way, a three-dimensional compressor map with data correlating compressor power, compressor speed, and Tcond may be derived for a specific compressor based on test data. Compressor current may be used instead of compressor power. Compressor power, however, may be preferred over compressor current to reduce the impact of any line voltage variation. The compressor map may be stored in a computer readable medium accessible to control module 25.
After measuring or calculating Tcond, control module 25 may calculate DSH as the difference between Tcond and DLT, with DLT data being receiving from external DLT sensor 28 or internal DLT sensor 30 (as shown in FIG. 8).
As further described in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference, Tevap may be a function of compressor power, compressor speed, and DLT. Control module 25 may derive Tevap based on compressor power or current, compressor speed, and DLT. Control module 25 may use Tevap to derive other parameters including compressor capacity, power, energy efficiency ratio, load, Kwh/Day, etc.
Control module 25 may determine mass flow based on delta T and by determining the applied heat of inverter drive 22. As shown in FIG. 7, mass flow may be derived based on lost heat of inverter drive 22 and delta T.
With reference to FIG. 7, inputs include compressor speed (RPM) 120, compressor current 122, compressor voltage 124, compressor power factor 126, Ti 128 and Ts 130. From compressor current 122, compressor voltage 124, and power factor 126, compressor power 132 is derived. From temperatures Ti 128 and Ts 130, delta T 134 is derived. From RPM 120 and power, Tcond 136 is derived. Also from RPM 120 and power 132, inverter heat loss 138 is derived. From inverter heat loss, and delta T 134, mass flow 140 is derived. From RPM 120, Tcond 136, and mass flow 140, Tevap 142 is derived. From Tevap 142 and Ts 130, SSH 144 is derived. From SSH 144 and ambient temperature as sensed by ambient temperature sensor 29, DSH 146 is derived. Once DSH 146 is derived, all of the benefits of the algorithms described above may be gained, including protection of compressor 10 from flood back and overheat conditions.
As shown by dotted line 141, Tcond and Tevap may be iteratively calculated to more accurately derive Tcond and Tevap. For example, optimal convergence may be achieved with three iterations. More or less iterations may also be used. Further, any of the calculated or derived variables described in FIG. 7 may alternatively be sensed or measured directly. In such the remaining variable may be calculated or derived based on the sensed or measured data.
DLT data may be received by an external DLT sensor 28. DLT sensor 28 may be a thermocouple located on the discharge tube extending from compressor 10. DLT data from DLT sensor 28 may correspond to a compressor discharge gas temperature. Alternatively, an internal DLT sensor 30 (as shown in FIG. 8), embedded within compressor 10, may be used. In other words, DLT sensor 30 may be incorporated inside compressor 10. In the case of a scroll compressor, DLT sensor 30 may be a thermistor exposed to the gas discharging from the compression mechanism and mounted on the non-orbiting scroll. The thermistor may be a positive temperature coefficient (PTC) or a negative temperature coefficient (NTC) thermistor. An internal DLT sensor, labeled as element 30, is shown in FIG. 8, mounted on the non-orbiting scroll of compressor 10.
In addition to deriving Tcond or Tevap from compressor power and compressor speed, Tcond or Tevap may be measured directly with a sensor. The derived Tcond or Tevap may be compared with the measured Tcond or Tevap. Based on the comparison, control module 25 may calibrate the derived parameter against the measured parameter to more accurately determine actual Tcond or Tevap.
With reference to FIG. 1, condenser 12 includes a condenser temperature sensor 42 that generates a signal corresponding to Tcond. Condenser sensor temperature 42 is connected to control module 25. In this way, control module 25 receives the Tcond measurement from condenser temperature sensor 42. Alternatively, a condenser pressure sensor may be used instead of condenser temperature sensor 42.
As shown in FIG. 2, an algorithm for calibrating Tcond begins in step 300. In step 302, condenser temperature sensor 42 may measure Tcond and communicate Tcond to control module 25. In step 304, control module 25 may calculate Tcond from compressor power and compressor speed data from inverter drive 22, as described above and in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference.
In step 306, control module 25 may compare the sensed Tcond with the calculated Tcond. In step 308, control module 25 may determine a difference between the sensed Tcond and the calculated Tcond. When the difference is less than a predetermined threshold in step 308, control module 25 may proceed to step 310. In step 310, control module 25 may calibrate the calculated Tcond with the measured Tcond.
Calibration may include updating compressor map data to more accurately reflect the measured Tcond. In this way, over time control module 25 may “learn” more accurate compressor map data for the compressor and may consequently be able to more accurately derive Tcond. Compressor map data may be stored in a computer readable medium accessible to control module 25. In addition, calibration may include determining an error parameter for condenser temperature sensor 42.
Thus, by measuring Tcond, calculating Tcond, and checking the measurement against the calculation, control module 25 may determine actual Tcond with high accuracy. The algorithm may end in step 312.
In step 308, when the difference is greater than the predetermined threshold, control module 25 may proceed to step 314 and determine whether the measured Tcond or the calculated Tcond is more accurate for use. Control module 25 may compare each of the measurement and the calculation to historical data for Tcond to determine which is closer to the historical Tcond. In this way, control module 25 may determine if the measurement or the calculation is correct for subsequent use.
In step 316, control module may then use the Tcond that is more accurate for subsequent calculations. In other words, control module 25 may proceed based on the Tcond (either sensed or derived) that is more accurate. In addition, control module 25 may generate an alarm to indicate a problem. For example, if control module 25 determines that the calculation is more accurate, condenser temperature sensor 42 may have malfunctioned. Control module 25 may generate an alarm to indicate that there has been a malfunction related to temperature condenser sensor 42. In addition, if control module 25 determines that the Tcond measurement is more accurate, control module 25 may generate an alarm to indicate a problem with the Tcond calculation. For example, an inaccurate calculation may be an indication of a malfunction of inverter drive 22 or that inverter drive 22 is not accurately reporting compressor speed or compressor power data.
As shown in FIG. 3, refrigeration system 5 may include evaporator 16 with an evaporator temperature sensor 40. An evaporator pressure sensor may alternatively be used. Evaporator temperature sensor 40 generates a signal corresponding to evaporator temperature and communicates Tevap to control module 25. Refrigeration system 5 may also include DLT sensor 28 for generating a DLT signal corresonding to DLT.
As shown in FIG. 4, an algorithm to calibrate Tevap starts in step 400. In step 402, evaporator temperature sensor 40 measures Tevap and reports Tevap to control module 25. In step 404, control module 25 calculates Tevap from compressor power, compressor speed data from inverter drive 22, and DLT.
In step 406, control module 25 compares the sensed or measured Tevap with the calculated Tevap. In step 408, control module 25 calculates a difference between the sensed Tevap and the calculated Tevap. When the difference is less than a predetermined threshold, control module 25 may proceed to step 410 and calibrate derived Tevap with measured Tevap. As with Tcond described above, control module 25 may update compressor map data if necessary to more accurately reflect measured Tevap. In this way, control module 25 may over time “learn” more accurate compressor map data. In addition, control module 25 may calculate an error parameter for evaporator temperature sensor 40. After step 410, the algorithm may end in step 412.
In step 408 when the difference is greater than the predetermined threshold, control module 25 may proceed to step 414 and determine whether the sensed or derived Tevap is more accurate for subsequent use. As with Tcond described above, control module 25 may compare both the sensed and calculated Tevap with historical data of Tevap to determine which is more accurate. When control module 25 has determined which Tevap is more accurate, control module 25 may proceed to step 416 and use the more accurate Tevap for subsequent calculations. In addition, control module 25 may generate an alarm indicating a problem with the Tevap measurement or calculation. For example, if the calculated Tevap is more accurate, control module 25 may generate an alarm indicating a malfunction associated with evaporator temperature sensor 40. If control module 25 determines that the measured Tevap is more accurate, control module 25 may generate an alarm indicating a malfunction associated with inverter drive 22. For example, inverter drive 22 may have malfunctioned with respect to calculating or reporting compressor speed, compressor power data, or DLT.
In this way, control module 25 may generate accurate Tevap and Tcond data for subsequent use in additional diagnostic, control and protection algorithms as described above and in the disclosure titled “VARIABLE SPEED COMPRESSOR PROTECTION SYSTEM AND METHOD”, U.S. Application Ser. No. 60/978,258, which is incorporated herein by reference.
a control module connected to said inverter drive that determines a measured condenser temperature based on said condenser signal, that monitors electric power data and compressor speed data from said inverter drive, that calculates a derived condenser temperature based on said monitored electric power data, said monitored compressor speed data, and compressor map data for said compressor, said compressor map data functionally correlating electric power data and compressor speed data with condenser temperature data for said compressor, and that compares said measured condenser temperature with said derived condenser temperature, and selectively updates said compressor map data based on said comparison.
2. The system of claim 1 wherein said control module calculates a difference between said derived condenser temperature and said calculated condenser temperature, compares said difference with a predetermined threshold, and selects one of said derived condenser temperature and said calculated condenser temperature as being more accurate when said difference is greater than said predetermined threshold.
3. The system of claim 2 wherein said control module generates an alarm when said difference is greater than said predetermined threshold.
selectively updating said compressor map data based on said comparing.
5. The method of claim 4 further comprising calculating a difference between said derived condenser temperature and said calculated condenser temperature, comparing said difference with a predetermined threshold, and selecting one of said derived condenser temperature and said calculated condenser temperature as being more accurate when said difference is greater than said predetermined threshold.
6. The method of claim 4 further comprising generating an alarm when said difference is greater than said predetermined threshold.
a control module connected to said inverter drive that determines a measured evaporator temperature based on said evaporator signal, that monitors electric power data and compressor speed data from said inverter drive, that calculates a derived evaporator temperature based on said monitored electric power data, said monitored compressor speed data, said discharge temperature signal, and compressor map data for said compressor, said compressor map data functionally correlating electric power data, compressor speed data, and discharge temperature data with evaporator temperature data for said compressor, that compares said measured condenser temperature with said derived condenser temperature, and that selectively updates said compressor map data based on said comparison.
8. The system of claim 7 wherein said control module calculates a difference between said derived evaporator temperature and said calculated evaporator temperature, compares said difference with a predetermined threshold, and selects one of said derived evaporator temperature and said calculated evaporator temperature as being more accurate when said difference is greater than said predetermined threshold.
9. The system of claim 8 wherein said control module generates an alarm when said difference is greater than said predetermined threshold.
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