Source: http://www.google.com/patents/US8157538?dq=5463388
Timestamp: 2014-03-08 20:16:09
Document Index: 162432303

Matched Legal Cases: ['Application No. 60', 'Application No. 04022920', 'Application No. 200610128576', 'Application No. 2008294060', 'Application No. 200410085953', 'Application No. 200610128576', 'Application No. 2008294060', 'Application No. 200610128576']

Patent US8157538 - Capacity modulation system for compressor and method - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAn apparatus is provided and may include a compression mechanism, a valve plate associated with the compression mechanism and having at least one port in fluid communication with the compression mechanism, and a manifold disposed adjacent to the valve plate. A cylinder may be formed in the manifold and...http://www.google.com/patents/US8157538?utm_source=gb-gplus-sharePatent US8157538 - Capacity modulation system for compressor and methodAdvanced Patent SearchPublication numberUS8157538 B2Publication typeGrantApplication numberUS 12/177,528Publication dateApr 17, 2012Filing dateJul 22, 2008Priority dateJul 23, 2007Also published asCN101772643A, CN101772643B, EP2181263A2, US20090028723, US20120177508, WO2009029154A2, WO2009029154A3Publication number12177528, 177528, US 8157538 B2, US 8157538B2, US-B2-8157538, US8157538 B2, US8157538B2InventorsFrank S. Wallis, Mitch M. Knapke, Ernest R. BergmanOriginal AssigneeEmerson Climate Technologies, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (109), Non-Patent Citations (21), Referenced by (1), Classifications (12), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetCapacity modulation system for compressor and methodUS 8157538 B2Abstract An apparatus is provided and may include a compression mechanism, a valve plate associated with the compression mechanism and having at least one port in fluid communication with the compression mechanism, and a manifold disposed adjacent to the valve plate. A cylinder may be formed in the manifold and a piston may be disposed within the manifold and may be movable relative to the manifold between a first position separated from the valve plate and a second position engaging the valve plate. A valve element may be disposed within the piston and may be movable relative to the piston and the manifold. The valve element may be movable between an open position spaced apart from the valve plate and permitting flow through the port and into the compression mechanism and a closed position engaging the valve plate and restricting flow through the port and into the compression mechanism.
a valve plate associated with said compression mechanism and including at least one port in fluid communication with said compression mechanism;
a manifold disposed adjacent to said valve plate;
a cylinder formed in said manifold;
a piston disposed within said manifold and movable relative to said manifold between a first position separated from said valve plate and a second position contacting said valve plate;
a valve element disposed within said piston and movable relative to said piston and said manifold, said valve element movable between an open position spaced apart from said valve plate and permitting flow through said port and into said compression mechanism and a closed position engaging said valve plate and restricting flow through said port and into said compression mechanism.
2. The apparatus of claim 1, wherein said piston includes an inner volume having a pressurized fluid disposed therein.
3. The apparatus of claim 2, wherein said pressurized fluid imparts a force on said valve element to move said valve element against one end of said piston.
4. The apparatus of claim 2, wherein said pressurized fluid is discharge-pressure gas received from said compression mechanism.
5. The apparatus of claim 1, further comprising a chamber disposed between a top surface of said piston and an inner surface of said cylinder, said chamber selectively receiving a pressurized fluid to move said piston from said first position to said second position.
6. The apparatus of claim 5, wherein said pressurized fluid is discharge-pressure gas received from said compression mechanism.
7. The apparatus of claim 5, further comprising a valve member operable to selectively supply said chamber with pressurized fluid.
8. The apparatus of claim 7, wherein said valve member includes a solenoid valve.
9. The apparatus of claim 8, further comprising a check valve selectively allowing fluid communication between said solenoid valve and said chamber.
10. The apparatus of claim 7, wherein said valve member is responsive to a pressure differential between a vacuum pressure and an intermediate pressure.
11. The apparatus of claim 10, wherein said intermediate pressure is fed to a cavity defined by a slave piston seal and a slave piston.
12. The apparatus of claim 7, wherein said valve member includes a plurality of slave piston seals at least partially defining a plurality of cavities.
13. The apparatus of claim 1, wherein movement of said piston from said first position to said second position toward said port causes concurrent movement of said valve element toward said port.
14. The apparatus of claim 13, wherein said valve element engages said valve plate prior to engagement between said piston and said valve plate when said piston is moved from said first position to said second position.
15. The apparatus of claim 13, wherein said piston moves relative to said valve element when said valve element is in said closed position until said piston contacts said valve plate and is in said second position.
16. The apparatus of claim 13, wherein said valve element engages said valve plate causing relative movement between said piston and said valve element when said piston is moved from said first position to said second position.
17. The apparatus of claim 1, further comprising a seal disposed between said piston and said cylinder and including a seal chamber receiving a pressurized fluid that biases said piston into said first position.
a piston disposed within said cylinder and movable relative to said cylinder between a first position spaced apart from the valve plate to allow flow through the port and into said compression mechanism and a second position engaging the valve plate to restrict flow through the port and into said compression mechanism;
a seal disposed between said piston and said cylinder and including a seal chamber receiving a first pressurized fluid therein to bias said piston into said first position;
a control mechanism in fluid communication with said cylinder and selectively supplying a second pressurized fluid to said cylinder to move said piston against a force applied on said piston by said first pressurized fluid disposed within said seal chamber to move said piston from said first position to said second position.
19. The apparatus of claim 18, further comprising a valve element movable with said piston between said first position and said second position, said valve element engaging the valve plate to prevent flow through the port when said piston is in said second position.
20. The apparatus of claim 19, wherein said valve element is movable relative to said piston.
21. The apparatus of claim 19, wherein said valve element contacts the valve plate prior to said piston reaching said second position.
22. The apparatus of claim 21, wherein contact between said valve element and the valve plate causes relative movement between said piston and said valve element.
23. The apparatus of claim 22, wherein said relative movement occurs until said piston engages the valve plate.
24. The apparatus of claim 18, wherein said seal is fixed relative to said cylinder.
25. The apparatus of claim 18, wherein said pressurized fluid is discharge-pressure gas received from the compressor.
26. The apparatus of claim 18, further comprising an injection port formed through said piston to place an interior volume of said piston in fluid communication with said seal chamber, said seal chamber supplying said interior volume with said first pressurized fluid via said injection port.
27. The apparatus of claim 26, further comprising a valve element slidably supported within said piston and urged against a first end of said piston by said first pressurized fluid disposed within said interior volume.
28. The apparatus of claim 18, wherein said control mechanism includes a solenoid valve.
29. The apparatus of claim 18, further comprising a check valve selectively allowing fluid communication between said solenoid valve and said piston.
30. The apparatus of claim 18, wherein said valve mechanism includes a cavity at least partially defined by an isolation seal and a slave piston.
31. The apparatus of claim 30, wherein a feed drilling provides fluid communication between said cavity and a system suction pressure port.
32. The apparatus of claim 30, wherein an intermediate pressure is supplied to said cavity to bias said slave piston toward an upward position.
33. The apparatus of claim 32, wherein valve mechanism allows discharge gas to evacuate through a vacuum port to when said slave piston is in said upward position.
34. The apparatus of claim 18, further comprising a chamber disposed within said cylinder between an inner surface of the manifold and an outer surface of said piston, said chamber in fluid communication with said control mechanism.
35. The apparatus of claim 34, wherein said control mechanism selectively supplies said chamber with said second pressurized fluid to move said piston from said first position to said second position.
36. The apparatus of claim 34, wherein said control mechanism selectively vents said chamber to allow said first pressurized fluid disposed within said seal chamber to move said piston from said second position to said first position. Description
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 60/951,274 filed on Jul. 23, 2007. The disclosure of the above application is incorporated herein by reference.
FIELD The present disclosure relates generally to compressors and more particularly to a capacity modulation system and method for a compressor.
BACKGROUND Heat pump and refrigeration systems are commonly operated under a wide range of loading conditions due to changing environmental conditions. In order to effectively and efficiently accomplish a desired cooling and/or heating under these changing conditions, conventional heat pump or refrigeration systems may incorporate a compressor having a capacity modulation system that adjusts an output of the compressor based on the environmental conditions.
SUMMARY An apparatus is provided and may include a compression mechanism, a valve plate associated with the compression mechanism and having at least one port in fluid communication with the compression mechanism, and a manifold disposed adjacent to the valve plate. A cylinder may be formed in the manifold and a piston may be disposed within the manifold and may be movable relative to the manifold between a first position separated from the valve plate and a second position engaging the valve plate. A valve element may be disposed within the piston and may be movable relative to the piston and the manifold. The valve element may be movable between an open position spaced apart from the valve plate and permitting flow through the port and into the compression mechanism and a closed position engaging the valve plate and restricting flow through the port and into the compression mechanism.
An apparatus is provided and may include a compression mechanism, a valve plate associated with the compression mechanism and having at least one port in fluid communication with the compression mechanism, and a manifold disposed adjacent to the valve plate. A cylinder may be formed in the manifold and a piston may be disposed within the cylinder and may be movable relative to the cylinder between a first position spaced apart from the valve plate to allow flow through the port and into the compression mechanism and a second position engaging the valve plate to restrict flow through the port and into the compression mechanism. A seal may be disposed between the piston and the cylinder and may include a seal chamber receiving pressurized fluid therein to bias the piston into the first position. A valve mechanism may be in fluid communication with the cylinder and may selectively supply pressurized fluid to the cylinder to move the piston against a force applied on the piston by the pressurized fluid disposed within the seal chamber to move the piston from the first position to the second position.
An apparatus is provided and may include a compression mechanism, a valve plate associated with the compression mechanism, and a pressure-responsive unloader valve movable between a first position permitting flow through the valve plate and into the compression mechanism and a second position restricting flow through the valve plate and into the compression mechanism. A control valve may move the unloader valve between the first position and the second position and may include at least one pressure-responsive valve member movable between a first state supplying discharge-pressure gas to the unloader valve to urge the unloader valve into one of the first position and the second position and a second state venting the discharge-pressure gas from the unloader valve to move the unloader valve into the other of the first position and the second position.
A method is provided and may include selectively providing a chamber with a control fluid, applying a force on a first end of a piston disposed within the chamber by the control fluid, and providing an interior volume of the piston with the control fluid. The method may further include applying a force on a disk disposed within the piston by the control fluid to urge the disk to a second end of the piston, moving the piston and the disk relative to the chamber under force of the control fluid, contacting a valve plate of a compressor with the disk, and contacting the valve plate of the compressor with a body of the piston following contact of the disk and the valve plate.
A method is provided and may include selectively providing a chamber with a control fluid, applying a force on a first end of a piston disposed within the chamber by the control fluid to move the piston in a first direction relative to the chamber, and directing the control fluid through a bore formed in the piston to open a valve and permit the control fluid to pass through the piston. The method may further include communicating the control fluid to an unloader valve to move the unloader valve into one of a first position permitting suction-pressure gas to a combustion chamber of a compressor and a second position preventing suction-pressure gas to the combustion chamber of the compressor.
DETAILED DESCRIPTION The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. The present teachings are suitable for incorporation in many different types of scroll and rotary compressors, including hermetic machines, open drive machines and non-hermetic machines.
The compressor 10 may include a manifold 12, a compression mechanism 14, and a discharge assembly 16. The manifold 12 may be disposed in close proximity to the valve plate 107 and may include at least one suction chamber 18. The compression mechanism 14 may similarly be disposed within the manifold 12 and may include at least one piston 22 received generally within a cylinder 24 formed in the manifold 12. The discharge assembly 18 may be disposed at an outlet of the cylinder 24 and may include a discharge-valve 26 that controls a flow of discharge-pressure gas from the cylinder 24.
When a pressurized fluid is communicated to the chamber 120, the piston 110 moves against valve opening 106 to prohibit fluid flow therethrough. In an application where the piston 110 blocks fluid flow to a suction inlet of a compressor 10 for �unloading� the compressor, the piston 110 may be referred to as an unloader piston. In such a compressor application, the pressurized fluid may be provided by the discharge-pressure gas of the compressor 10. Suction-pressure gas from the suction chamber 18 of the compressor 10 may also be communicated to the chamber 120, to bias the piston 110 away from the valve opening 106. Accordingly, the piston 110 is movable relative to the valve opening 106 to allow or prohibit fluid communication to passage 104.
As shown in FIG. 1, the piston 110 has a disc-shaped sealing element 140 slidably disposed in a lower portion of the piston 110. The retaining member 118 is disposed at the lower portion of the piston 110, and engages the disc-shaped sealing element 140 to retain the sealing element 140 within the lower end portion of the piston 110. The slidable arrangement of the sealing element 140 within the piston 110 permits movement of the piston 110 relative to the sealing element 140 when the sealing element 140 closes off the valve opening 106. When discharge-pressure gas is communicated to the chamber 120, the force of the discharge-pressure gas acting on the top of the piston 110 causes the piston 110 and sealing element 140 to move towards the raised valve seat 108 adjacent the valve opening 106. The disc-shaped sealing element 140 is held down against the valve opening 106 by the discharge-pressure gas applied on top of the disc-shaped sealing element 140. Suction-pressure gas is also disposed under the sealing element 140 at the annulus between the seal C and valve seat 108.
As shown in FIG. 1, the thickness of the retaining member 118 is less than the height of the valve seat 108. The relative difference between the height of the retaining member 118 and the valve seat 108 is such that the sealing element 140 engages and closes off the valve seat 108 before the bottom of the piston 110 reaches the valve plate 107 in which the valve opening 106 and valve seat 108 are located. Specifically, the thickness of the retaining member or lip 118 is less than the height of the valve seat 108, such that when the sealing element 140 engages the valve seat 108, the retaining member 118 has not yet engaged the valve plate 107. The piston 110 may then continue to move or travel over and beyond the point of closure of the sealing element 140 against the valve seat 108, to a position where the retaining element 118 engages the valve plate 107.
The above �over-travel� distance is the distance that the piston 110 may travel beyond the point the sealing element 140 engages and becomes stationary against the valve seat 108, before the retaining member 118 seats against the valve plate 107. This �over-travel� of the piston 110 results in relative movement between the piston 110 and the sealing element 140. Such relative movement results in the displacement of the seal C and seal carrier 142 against the pressure within the inside of the piston 110, which provides a force for holding the sealing element 140 against the valve seat 108. The amount of �over-travel� movement of the piston cylinder 114 relative to the sealing disc element 140 may result in a slight separation (or distance) D between the retaining member 118 and the sealing element 140, as shown in FIG. 1. In one configuration, the amount of over travel may be in the range of 0.001 to 0.040 inches, with a nominal of 0.020 inches.
Referring to FIGS. 3 and 4, the piston 110 is shown in the open state relative to the valve opening 106. Chamber 120 may be placed in communication with a low pressure fluid source (such as suction pressure gas from a compressor, for example) to allow the piston 110 to move away from the valve opening 106 and permit suction flow therethrough. A valve member 126 (shown in FIGS. 5 and 6) must move from a first position (FIG. 5) to a second position (FIG. 6) in order to supply low pressure gas into control-pressure passage 124 and chamber 120. Only after low pressure gas (e.g., suction pressure gas) is in chamber 120 will the piston 110 be urged upward. In other words, high pressure gas is trapped in chamber 120 until the chamber 120 is vented to suction pressure by the movement of valve member 126 into the second position. The piston 110 is maintained in the open state while a low pressure or suction pressure is communicated to the chamber 120. In this state, the piston 110 is positioned for full capacity, with suction gas flowing unrestricted through valve opening 106 and into a suction passage 104 within the valve plate 107. Suction-pressure gas in communication with the chamber 120 above the piston 110 allows the piston 110 to move in an upward direction relative to the body 102. Suction-pressure gas may be in communication with the chamber 120 via the suction passage 104 in the valve plate 107.
The valve member 126 is movable between the first position shown in FIG. 5, and the second position shown in FIG. 6, depending on the application of high-pressure gas to the valve member 126. When the valve member 126 is in communication with a pressurized fluid, the valve member 126 is moved to the first position, as shown in FIG. 5. The pressurized fluid may be a discharge pressure gas from a compressor, for example.
The slave piston 160 remains seated against a seal surface 166 when a pressurized fluid is in communication with the slave piston 160. The pressurized fluid may be a discharge pressure gas from a compressor, for example. When pressurized fluid is in communication with the volume above the slave piston 160, the pressurized fluid is allowed to flow through the pressure-responsive slave piston 160 via hole 178 in the center of the slave piston 160 and past the check-valve ball 164. This pressurized fluid, which is at or near discharge pressure, is communicated to the chamber 120 for pushing the piston 110 down against valve opening 106, as previously explained, such that suction flow is blocked and the compressor 10 is �unloaded.� There is a pressure-drop past the check-valve ball 164, as a result of the pressurized fluid acting to overcome the force of the spring 162 biasing the check-valve ball 164 away from the hole 178. This pressure differential across the slave piston 160 is enough to push the slave piston 160 down against surface 166 to provide a seal. This seal effectively traps or restricts high pressure gas to the common port 170 leading to the control-pressure passage 124. The control-pressure passage 124 may be in communication with one or more chambers 120 for opening or closing one or more pistons 110. The common port 170 and control-pressure passage 124 directs discharge-pressure gas to chamber 120 against the piston 110, to thereby push the piston 110 down.
Referring to FIG. 6, the slave piston 160 (or valve member 126) is shown in a second position, where communication of pressurized fluid or discharge-pressure gas to the slave piston 160 is prohibited. In this position, the valve chamber is in communication with the suction-pressure passage 186, such that the piston 110 is moved into the �loaded� position. The internal volume of the chamber or passage 184 between the solenoid valve 130 and the slave piston 160 is as small as practical (considering design and economic limitations), such that the amount of trapped pressurized fluid therein may be bled off quickly to effectuate a fast closure of the piston 110. When communication of pressurized fluid to the slave piston 160 is discontinued, the pressure trapped above the slave piston bleeds past the vent orifice 174. As the pressure drops above the slave piston 160 the check valve 164 is closed against hole 178, which prevents pressure in the common port 170 from flowing into the chamber above the slave piston 160. The common port 170 that feeds the chamber 120 above the piston 110 may also be referred to as the �common� port, particularly where the valve apparatus 100 includes a plurality of pistons 110.
Referring now to FIG. 10, another embodiment of a valve is provided that includes a plurality of pistons 410 (shown raised and lowered for illustration purposes only), each having a reed or valve ring 440 slidably disposed within the lower end of the piston 410. Operation of the valve ring 440 is similar to the sealing element 140 previously discussed in that discharge-pressure gas on top of the valve ring 440 holds the valve ring 440 against the valve seat 408 when the piston 410 is moved to the �down� position. Discharge-pressure gas above seal C is confined by the outside and inside diameter of the seal C. The valve ring 440 is loaded against the valve seat 408 by the pressure in the piston 410 acting against seal C, which has a high pressure above the seal C and a lower pressure (system suction and/or a vacuum) under the seal C. When the piston 410 is in the unloaded (downward) position and the valve ring 440 is against the valve seat 408, suction gas has the potential to leak between the upper surface of the valve ring 440 and the bottom surface of Seal C. The surface finish and design characteristics of seal C must be appropriately selected to prevent leakage at the interface between the upper surface of the valve ring 440 and the bottom surface of Seal C.
The use of a porting plate 480 provides a means for routing suction or discharge-pressure gas from the solenoid valve 430 to the chambers 420 on top of single or multiple pistons 410. The port on the solenoid valve 430 that controls the flow of gas to load or unload the pistons 410 is referred to as the �common� port 470, which communicates via control-pressure passage 424 to chambers 420. The solenoid valve 430 in this application may be a three-port valve in communication with suction and discharge-pressure gas and a common port 470 that is charged with suction or discharge-pressure gas depending on the desired state of the piston 410.
Capacity may be regulated by opening and closing one or more of the plurality of pistons 410 to control flow capacity. A predetermined number of pistons 410 may be used, for example, to block the flow of suction gas to a compressor, for example. The percentage of capacity reduction is approximately equal to the ratio of the number of �blocked� cylinders to the total number of cylinders. Capacity reduction may be achieved by the various disclosed valve mechanism features and methods of controlling the valve mechanism. The valve's control of discharge-pressure gas and suction-pressure gas may also be used in either a blocked suction application or in a manner where capacity is modulated by activating and de-activating the blocking pistons 410 in a duty-cycle fashion. Using multiple pistons 410 to increase the available flow area will result in increased full-load compressor efficiency.
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