US20080216494A1 - Compressor data module - Google Patents

Abstract

A compressor includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a processor and a memory. The compressor controller includes a processor and a memory. The data module receives sensed data, stores sensed data in the memory, and communicates sensed data to the compressor controller. The compressor controller controls a capacity of the compressor based on the sensed data and is operable to communicate with a system controller of a refrigeration system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims the benefit of U.S. Provisional Application No. 60/842,898, filed on Sep. 7, 2006. The disclosure of the above application is incorporated herein by reference.
FIELD
• The present disclosure relates to compressors, and more particularly, to a data module for use with a compressor.
BACKGROUND
• The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
• Compressors are used in a wide variety of industrial and residential applications to circulate refrigerant within a refrigeration, heat pump, HVAC, or chiller system (generically referred to as “refrigeration systems”) to provide a desired heating and/or cooling effect. In any of the foregoing applications, the compressor should provide consistent and efficient operation to ensure that the particular refrigeration system functions properly.
• Refrigeration systems and associated compressors may include a protection device that intermittently restricts power to the compressor to prevent operation of the compressor and associated components of the refrigeration system (i.e., evaporator, condenser, etc.) when conditions are unfavorable. For example, when a particular fault or failure is detected within the compressor, the protection device may restrict power to the compressor to prevent operation of the compressor and refrigeration system under such conditions.
• The types of faults that may cause protection concerns include electrical, mechanical, and system faults. Electrical faults typically have a direct effect on an electrical motor associated with the compressor, while mechanical faults generally include faulty bearings or broken parts. Mechanical faults often raise a temperature of working components within the compressor and, thus, may cause malfunction of, and possible damage to, the compressor.
• In addition to electrical and mechanical faults associated with the compressor, the refrigeration system components may be affected by system faults attributed to system conditions such as an adverse level of fluid disposed within the system or to a blocked-flow condition external to the compressor. Such system conditions may raise an internal compressor temperature or pressure to high levels, thereby damaging the compressor and causing system inefficiencies and/or failures. To prevent system and compressor damage or failure, the compressor may be shut down by the protection system when any of the aforementioned conditions are present.
• Conventional protection systems may sense temperature and/or pressure parameters as discrete switches to interrupt power supplied to the electrical motor of the compressor should a predetermined temperature or pressure threshold be exceeded. Such systems typically employ multiple temperature and pressure sensors to detect operating parameters of the compressor, which results in a complex and costly protection system.
• Because conventional protection systems directly control a compressor to which they are tied, conventional protection systems cannot be used with multiple control modules, and may only be used with a single compressor and a single controller.
SUMMARY
• A compressor includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a processor and a memory. The compressor controller includes a processor and a memory. The data module receives sensed data, stores sensed data in the memory, and communicates sensed data to the compressor controller. The compressor controller controls a capacity of the compressor based on the sensed data and is operable to communicate with a system controller of a refrigeration system.
• In a refrigeration system that includes a system controller in communication with a compressor controller associated with a compressor, a data module includes a housing, a processor and a memory. The housing is mountable on the compressor and the processor receives sensed data, stores sensed data in the memory, and is operable to communicate sensed data to the compressor controller.
• A compressor control system includes a compressor and a compressor controller that is operable to diagnose and/or control the compressor. A data module is associated with the compressor, is in communication with the compressor controller, and receives sensor data indicative of compressor performance. It further determines non-measured system operating parameters and diagnoses the compressor based on at least one of the sensor data and the non-measured system operating parameters. The data module further communicates the sensor data, the non-measured system operating parameters, and the diagnosis to the compressor controller.
• A method includes communicating sensor data to a data module, processing the sensor data at the data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system, and processing at least one of the sensor data and the determined non-measured operating parameters at the data module to diagnose the at least one compressor and refrigeration system. A method further includes communicating the sensor data, the non-measured operating parameters, and the diagnosis to a system controller. The non-measured operating parameters are determined at the system controller based on the received sensor data and the diagnosis at the system controller is determined based on the received sensor data and the non-measured operating parameters. The received non-measured operating parameters are compared to the determined non-measured operating parameters at the system controller and the received diagnosis is compared to the determined diagnosis at the system controller.
• A method further includes communicating sensor data to a data module and processing the sensor data at the data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system. At least one of the sensor data and the non-measured operating parameters are processed at the data module to diagnose the at least one compressor and refrigeration system. At least one of the sensor data, the non-measured operating parameters, and the diagnosis is stored in a memory of the data module. At least one of the sensor data, the non-measured operating parameters, and the diagnosis is communicated to a first system controller. The first system controller is replaced with a second system controller. At least one of the stored sensor data, the stored non-measured operating parameters, and the stored diagnosis is communicated to the second controller.
• Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
• The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
• FIG. 1 is a perspective view of a compressor incorporating a data module in accordance with the principles of the present teachings;
• FIG. 2 is a cross-sectional view of the compressor ofFIG. 1;
• FIG. 3 is a schematic representation of a refrigeration system incorporating the compressor ofFIG. 1;
• FIG. 4 is a table illustrating various sensor combinations used to determine various compressor and system operating parameters;
• FIG. 5 is a graph of compressor current versus condenser temperature for use in determining condenser temperature at a given evaporator temperature;
• FIG. 6 is a graph of discharge temperature versus evaporator temperature for use in determining an evaporator temperature at a given condenser temperature;
• FIG. 7 is a graph of discharge superheat versus suction superheat to determine suction superheat at a given outdoor/ambient temperature;
• FIG. 8 is a schematic representation of the data module ofFIG. 1 shown in communication with a diagnostic and control module and a plurality of sensors;
• FIG. 9 is a more detailed schematic representation of the data module ofFIG. 1; and
• FIG. 10 is a schematic representation of another data module for use with the compressor ofFIG. 1 incorporating a diagnostic and control module and in communication with a plurality of sensors.
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. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that proved the described functionality.
• With reference to the drawings, acompressor10 is shown incorporating a protection andcontrol system12. The protection andcontrol system12 utilizes a series of sensors and non-measured operating parameters derived from information received from the sensors to diagnose thecompressor10 andrefrigeration system11 to which thecompressor10 may be tied. The protection andcontrol system12 includes adata module14 and a diagnostics andcontrol module15. Thedata module14 may provide multiple levels of data for use by the diagnostics andcontrol module15 in diagnosing and controlling thecompressor10 and/orrefrigeration system11. For example, thedata module14 may provide three levels of data for use by the diagnostics andcontrol module15, including sensor data, non-measured operating parameters (i.e., processed sensor data), and diagnostics for use by the diagnostics andcontrol module15 in diagnosing and controlling thecompressor10 and/orrefrigeration system11.
• The data provided by thedata module14 is not controller specific. Therefore, thedata module14 may be used with any control module. Providing thedata module14 with the ability to be used with any control module allows thedata module14 flexibility in that thedata module14 may be used with various controllers of various manufacturers and configurations.
• With particular reference toFIGS. 1 and 2, thecompressor10 is shown to include a generally cylindricalhermetic shell17 having a weldedcap16 at a top portion and a base18 having a plurality offeet20 welded at a bottom portion. Thecap16 and the base18 are fitted to theshell17 such that aninterior volume22 of thecompressor10 is defined. Thecap16 is provided with a discharge fitting24, while theshell17 is similarly provided with an inlet fitting26, disposed generally between thecap16 andbase18, as best shown inFIG. 2. In addition, anelectrical enclosure28 is fixedly attached to theshell17 generally between thecap16 and thebase18 and supports a portion of the protection andcontrol system12 therein.
• Acrankshaft30 is rotatably driven by an electric motor32 relative to theshell17. The motor32 includes astator34 fixedly supported by thehermetic shell17,windings36 passing therethrough, and arotor38 press-fit on thecrankshaft30. The motor32 and associatedstator34,windings36, androtor38 cooperate to drive thecrankshaft30 relative to theshell17 to compress a fluid.
• Thecompressor10 further includes anorbiting scroll member40 having a spiral vein or wrap42 on an upper surface thereof for use in receiving and compressing a fluid. AnOldham coupling44 is disposed generally between the orbitingscroll member40 and bearinghousing46 and is keyed to theorbiting scroll member40 and anon-orbiting scroll member48. TheOldham coupling44 transmits rotational forces from thecrankshaft30 to theorbiting scroll member40 to compress a fluid disposed generally between the orbitingscroll member40 and thenon-orbiting scroll member48.Oldham coupling44, and its interaction with orbitingscroll member40 andnon-orbiting scroll member48, is preferably of the type disclosed in assignee's commonly owned U.S. Pat. No. 5,320,506, the disclosure of which is incorporated herein by reference.
• Non-orbiting scroll member48 also includes awrap50 positioned in meshing engagement with thewrap42 of theorbiting scroll member40.Non-orbiting scroll member48 has a centrally disposeddischarge passage52, which communicates with an upwardly open recess54. Recess54 is in fluid communication with the discharge fitting24 defined by thecap16 and apartition56, such that compressed fluid exits theshell17 viadischarge passage52, recess54, and fitting24.Non-orbiting scroll member48 is designed to be mounted to bearinghousing46 in a suitable manner such as disclosed in assignee's commonly owned U.S. Pat. Nos. 4,877,382 and 5,102,316, the disclosures of which are incorporated herein by reference.
• Theelectrical enclosure28 includes alower housing58, anupper housing60, and acavity62. Thelower housing58 is mounted to theshell17 using a plurality of studs64, which are welded or otherwise fixedly attached to theshell17. Theupper housing60 is matingly received by thelower housing58 and defines thecavity62 therebetween. Thecavity62 is positioned on theshell17 of thecompressor10 and may be used to house respective components of the protection andcontrol system12 and/or other hardware used to control operation of thecompressor10 and/orrefrigeration system11.
• With particular reference toFIG. 2, thecompressor10 includes anactuation assembly65 that selectively separates theorbiting scroll member40 from thenon-orbiting scroll member48 to modulate a capacity of thecompressor10. Theactuation assembly65 may include a solenoid66 connected to theorbiting scroll member40 and a controller68 coupled to the solenoid66 for controlling movement of the solenoid66 between an extended position and a retracted position.
• Movement of the solenoid66 into the extended position separates thewraps42 of theorbiting scroll member40 from thewraps50 of thenon-orbiting scroll member48 to reduce an output of thecompressor10. Conversely, movement of the solenoid66 into the retracted position moves thewraps42 of theorbiting scroll member40 closer to thewraps50 of thenon-orbiting scroll member48 to increase an output of the compressor. In this manner, the capacity of thecompressor10 may be modulated in accordance with demand or in response to a fault condition.
• While movement of the solenoid66 into the extended position is described as separating thewraps42 of theorbiting scroll member40 from thewraps50 of thenon-orbiting scroll member48, movement of the solenoid66 into the extended position could alternately move thewraps42 of theorbiting scroll member40 into engagement with thewraps50 of thenon-orbiting scroll member48. Similarly, while movement of the solenoid66 into the retracted position is described as moving thewraps42 of theorbiting scroll member40 closer to thewraps50 of thenon-orbiting scroll member48, movement of the solenoid66 into the retracted position could alternately move thewraps42 of theorbiting scroll member40 away from thewraps50 of thenon-orbiting scroll member48. Theactuation assembly65 is preferably of the type disclosed in assignee's commonly owned U.S. Pat. No. 6,412,293, the disclosure of which is incorporated herein by reference.
• With particular reference toFIG. 3, therefrigeration system11 includes acondenser70, an evaporator72, and anexpansion device74 disposed generally between thecondenser70 and the evaporator72. Therefrigeration system11 also includes acondenser fan76 associated with thecondenser70 and anevaporator fan78 associated with the evaporator72. Each of thecondenser fan76 and theevaporator fan78 may be variable-speed fans that can be controlled based on a cooling and/or heating demand of therefrigeration system11. Furthermore, each of thecondenser fan76 andevaporator fan78 may be controlled by the protection andcontrol system12 such that operation of thecondenser fan76 andevaporator fan78 may be coordinated with operation of thecompressor10.
• In operation, thecompressor10 circulates refrigerant generally between thecondenser70 and evaporator72 to produce a desired heating and/or cooling effect. Thecompressor10 receives vapor refrigerant from the evaporator72 generally at the inlet fitting26 and compresses the vapor refrigerant between the orbitingscroll member40 and thenon-orbiting scroll member48 to deliver vapor refrigerant at discharge pressure at discharge fitting24.
• Once thecompressor10 has sufficiently compressed the vapor refrigerant to discharge pressure, the discharge-pressure refrigerant exits thecompressor10 at the discharge fitting24 and travels within therefrigeration system11 to thecondenser70. Once the vapor enters thecondenser70, the refrigerant changes phase from a vapor to a liquid, thereby rejecting heat. The rejected heat is removed from thecondenser70 through circulation of air through thecondenser70 by thecondenser fan76. When the refrigerant has sufficiently changed phase from a vapor to a liquid, the refrigerant exits thecondenser70 and travels within therefrigeration system11 generally towards theexpansion device74 and evaporator72.
• Upon exiting thecondenser70, the refrigerant first encounters theexpansion device74. Once theexpansion device74 has sufficiently expanded the liquid refrigerant, the liquid refrigerant enters the evaporator72 to change phase from a liquid to a vapor. Once disposed within the evaporator72, the liquid refrigerant absorbs heat, thereby changing from a liquid to a vapor and producing a cooling effect. If the evaporator72 is disposed within an interior of a building, the desired cooling effect is circulated into the building to cool the building by theevaporator fan78. if the evaporator72 is associated with a heat-pump refrigeration system, the evaporator72 may be located remote from the building such that the cooling effect is lost to the atmosphere and the rejected heat experienced by thecondenser70 is directed to the interior of the building to heat the building. In either configuration, once the refrigerant has sufficiently changed phase from a liquid to a vapor, the vaporized refrigerant is received by the inlet fitting26 of thecompressor10 to begin the cycle anew.
• With particular reference toFIGS. 2 and 3, the protection andcontrol system12 is shown to include acurrent sensor80, atemperature sensor82, a liquidline temperature sensor84, and an outdoor/ambient temperature sensor86. The protection andcontrol system12 also includesprocessing circuitry88,89, respectively associated with thedata module14 and diagnostics andcontrol module15, and apower interruption system90. Theprocessing circuitry88,89 andpower interruption system90 may be disposed within theelectrical enclosure28 mounted to theshell17 of the compressor10 (FIG. 2). Thesensors80,82,84,86 cooperate to provide theprocessing circuitry88 of thedata module14 with sensor data indicative of compressor and/or refrigeration system operating parameters for use by theprocessing circuitry88 in determining operating parameters of thecompressor10 and/orrefrigeration system11 that are not directly sensed by a sensor (hereinafter “non-measured operating parameters”). Theprocessing circuitry88 may use the sensor data to compute the non-measured operating parameters.
• Theprocessing circuitry88 may use the sensor data and/or non-measured operating parameters to diagnose thecompressor10 and/orrefrigeration system11. Thedata module14 may transmit the sensor data, derived non-measured operating parameters, and/or compressor/refrigeration system diagnosis to theprocessing circuitry89 of the diagnostics andcontrol module15 for use by theprocessing circuitry89 in diagnosing and controlling thecompressor10 and/orrefrigeration system11. Because thedata module14 provides compressor and/or refrigeration system operational data, thedata module14 is not controller specific and may be used with various control modules including diagnostics andcontrol module15. Operation of thedata module14 and diagnostics andcontrol module15 will be described in detail below.
• Thecurrent sensor80 may provide diagnostics related to high-side faults such as compressor mechanical failures, motor failures, and electrical component failures such as missing phase, reverse phase, motor winding current imbalance, open circuit, low voltage, locked rotor current, excessive motor winding temperature, welded or open contactors, and short cycling. Thecurrent sensor80 may monitor compressor current and voltage for use in determining and differentiating between mechanical failures, motor failures, and electrical component failures.
• Thecurrent sensor80 may be mounted within theelectrical enclosure28 or may alternatively be incorporated inside theshell17 of the compressor10 (FIG. 2). In either case, thecurrent sensor80 may monitor current drawn by thecompressor10 and generate a signal indicative thereof, such as disclosed in assignee's commonly owned U.S. Pat. No. 6,615,594, U.S. patent application Ser. No. 11/027,757 filed on Dec. 30, 2004, and U.S. patent application Ser. No. 11/059,646 filed on Feb. 16, 2005, the disclosures of which are incorporated herein by reference.
• While acurrent sensor80 is disclosed, the protection andcontrol system12 may also include a discharge-pressure sensor92 mounted in a discharge-pressure zone and/or atemperature sensor94 mounted within or near thecompressor shell17 such as within the discharge fitting24 (FIG. 2) or in an external system such as the condenser70 (FIG. 3). Thetemperature sensor94 may additionally or alternatively be positioned external of thecompressor10 along aconduit103 extending generally between thecompressor10 and the condenser70 (FIG. 3) and may be disposed in close proximity to an inlet of thecondenser70. Any or all of the foregoing sensors may be used in conjunction with thecurrent sensor80 to provide the protection andcontrol system12 with additional system information.
• Thetemperature sensor82 generally provides data related to low-side faults such as a low charge in the refrigerant, a plugged orifice, an evaporator fan failure, or a leak in thecompressor10. Thetemperature sensor82 may be disposed proximate to the discharge fitting24 or thedischarge passage52 of thecompressor10 and may monitor a discharge line temperature of a compressed fluid exiting thecompressor10. In addition to the foregoing, thetemperature sensor82 may be disposed external from thecompressor shell17 and proximate to the discharge fitting24 such that vapor at discharge pressure encounters thetemperature sensor82. Locating thetemperature sensor82 external of theshell17 allows flexibility in compressor and system design by providing thetemperature sensor82 with the ability to be readily adapted for use with practically any compressor and any system.
• While thetemperature sensor82 may provide discharge line temperature information, the protection andcontrol system12 may also include a suction-pressure sensor96 or a low-side temperature sensor98, which may be mounted proximate to an inlet of thecompressor10. In one configuration, thesuction pressure sensor96 or the low-side temperature sensor98 is located proximate to the inlet fitting26 (FIG. 2) or is mounted in an external system such as the evaporator72 (FIG. 3). The suction-pressure sensor96 and low-side temperature sensor98 may additionally or alternatively be disposed along aconduit105 extending generally between the evaporator72 and the compressor10 (FIG. 3) and may be disposed in close proximity to an outlet of the evaporator72. Any or all of the foregoing sensors may be used in conjunction with thetemperature sensor82 to provide the protection andcontrol system12 with additional system information.
• While thetemperature sensor82 may be positioned external to theshell17 of thecompressor10, the discharge temperature of thecompressor10 can similarly be measured within theshell17 of thecompressor10. A discharge-core temperature, taken generally at the discharge fitting24, could be used in place of the discharge line temperature arrangement shown inFIG. 2. A hermeticterminal assembly100 may be used with such an internal discharge temperature sensor to maintain the sealed nature of thecompressor shell17.
• The liquidline temperature sensor84 may be positioned either within thecondenser70 or may be positioned along aconduit102 extending generally between an outlet of thecondenser70 and theexpansion device74. In this position, thetemperature sensor84 is located in a position within therefrigeration system11 that represents a liquid location that is common to both a cooling mode and a heating mode if therefrigeration system11 is a heat pump. Because the liquidline temperature sensor84 is disposed generally near an outlet of thecondenser70 or along theconduit102 extending generally between the outlet of thecondenser70 and theexpansion device74, the liquidline temperature sensor84 encounters liquid refrigerant (i.e., after the refrigerant has changed from a vapor to a liquid within the condenser70) and therefore can provide an indication of a temperature of the liquid refrigerant to theprocessing circuitry88. While the liquidline temperature sensor84 is described as being near an outlet of thecondenser70 or along aconduit102 extending between thecondenser70 and theexpansion device74, the liquidline temperature sensor84 may also be placed anywhere within therefrigeration system11 that would allow the liquidline temperature sensor84 to provide an indication of a temperature of liquid refrigerant within therefrigeration system11 to theprocessing circuitry88.
• The outdoor/ambient temperature sensor86 may be located external from thecompressor shell17 and generally provides an indication of the outdoor/ambient temperature surrounding thecompressor10 and/orrefrigeration system11. The outdoor/ambient temperature sensor86 may be positioned adjacent to thecompressor shell17 such that the outdoor/ambient temperature sensor86 is in close proximity to the processing circuitry88 (FIGS. 2 and 3). Placing the outdoor/ambient temperature sensor86 in close proximity to thecompressor shell17 provides theprocessing circuitry88 of thedata module14 with a measure of the temperature generally adjacent to thecompressor10. Locating the outdoor/ambient temperature sensor86 in close proximity to thecompressor shell17 not only provides theprocessing circuitry88 with an accurate measure of the surrounding air around thecompressor10, but also allows the outdoor/ambient temperature sensor86 to be attached to or disposed within theelectrical enclosure28.
• Theprocessing circuitry88 of thedata module14 may receive sensor information from thecurrent sensor80,temperature sensor82, liquidline temperature sensor84, and outdoor/ambient temperature sensor86. As shown inFIG. 4, theprocessing circuitry88 uses the sensor data from therespective sensors80,82,84,86 to determine non-measured operating parameters of thecompressor10 and/orrefrigeration system11.
• Theprocessing circuitry88 may be able to determine non-measured operating parameters of thecompressor10 and/orrefrigeration system11 based on sensor data received from therespective sensors80,82,84,86 without requiring individual sensors for each of the non-measured operating parameters. Theprocessing circuitry88 may be able to determine condenser temperature (T_cond), subcooling of therefrigeration system11, a temperature difference between the condenser temperature and outdoor/ambient temperature condenser (TD), and a discharge superheat of therefrigeration system11.
• Theprocessing circuitry88 may determine the condenser temperature by referencing compressor power on a compressor map. The derived condenser temperature is generally the saturated condenser temperature equivalent to the discharge pressure for a particular refrigerant. The condenser temperature should be close to a temperature at a mid-point of thecondenser70. Using a compressor map to determine the condenser temperature provides a more accurate representation of the overall temperature of thecondenser70 when compared to a condenser temperature value provided by a temperature sensor mounted on a coil of thecondenser70, as the condenser coil likely includes many parallel circuits having different temperatures.
• FIG. 5 is an example of a compressor map showing compressor current versus condenser temperature at various evaporator temperatures (T_evap). As shown, current remains fairly constant irrespective of evaporator temperature. Therefore, while an exact evaporator temperature can be determined by a second degree polynomial (i.e., a quadratic function), for purposes of control, the evaporator temperature can be determined by a first degree polynomial (i.e., a linear function) and can be approximated as roughly 45, 50, or 55 degrees Fahrenheit. The error associated with choosing an incorrect evaporator temperature is minimal when determining the condenser temperature. While compressor current is shown, compressor power and/or voltage may be used in place of current for use in determining condenser temperature. Compressor power may be determined based on the current drawn by motor32, as indicated by thecurrent sensor80.
• Once the compressor current is known it may adjust for voltage based on a baseline voltage contained in a compressor map. The condenser temperature may be determined by comparing compressor current with condenser temperature using the graph shown inFIG. 5. The above process for determining the condenser temperature is described in assignee's commonly-owned U.S. patent application Ser. No. 11/059,646 filed on Feb. 16, 2005, the disclosure of which is herein incorporated by reference.
• Once the condenser temperature is known, theprocessing circuitry88 may then determine the subcooling of therefrigeration system11 by subtracting the liquid line temperature indicated by the liquidline temperature sensor84 from the condenser temperature and then subtracting an additional small value (typically 2-3° F.) representing the pressure drop between an outlet of thecompressor10 and an outlet of thecondenser70. Theprocessing circuitry88 is therefore able to determine not only the condenser temperature but also the subcooling of therefrigeration system11 without requiring an additional temperature sensor for either operating parameter.
• Theprocessing circuitry88 may also be able to calculate a temperature difference (TD) between thecondenser70 and the outdoor/ambient temperature surrounding therefrigeration system11. Theprocessing circuitry88 may determine the condenser temperature by referencing either the power or current drawn by thecompressor10 against the graph shown inFIG. 5 without requiring a temperature sensor to be positioned within thecondenser70. Once the condenser temperature is known (i.e., derived), theprocessing circuitry88 can determine the temperature difference (TD) by subtracting the ambient temperature as received from the outdoor/ambient temperature sensor86 from the derived condenser temperature.
• The discharge superheat of therefrigeration system11 may also be determined once the condenser temperature is known. Specifically, theprocessing circuitry88 may determine the discharge superheat of therefrigeration system11 by subtracting the condenser temperature from the discharge line temperature. As described above, the discharge line temperature may be detected by thetemperature sensor82 and is provided to theprocessing circuitry88. Because theprocessing circuitry88 can determine the condenser temperature by referencing the compressor power against the graph shown inFIG. 5, and because theprocessing circuitry88 knows the discharge line temperature based on information received from thetemperature sensor82, theprocessing circuitry88 can determine the discharge superheat of thecompressor10 by subtracting the condenser temperature from the discharge line temperature.
• Once the discharge superheat is determined, theprocessing circuitry88 can determine the suction superheat by referencing a plot as shown inFIG. 7. Specifically, the suction superheat may be determined by referencing the discharge superheat against the ambient temperature as indicated by the outdoor/ambient temperature sensor86.
• Once the condenser temperature is determined, theprocessing circuitry88 can reference a plot as shown inFIG. 6 to determine the exact evaporator temperature based on discharge temperature information received from thetemperature sensor82. Once both the condenser temperature and the evaporator temperature are known, theprocessing circuitry88 can then determine compressor capacity and flow.
• In addition to deriving the condenser temperature, evaporator temperature, subcooling, discharge superheat, compressor capacity and flow, and suction superheat, theprocessing circuitry88 may also measure or estimate the fan power of thecondenser fan76 and/orevaporator fan78 and derive a compressor power factor for use in determining the efficiency of therefrigeration system11 and the capacity of the evaporator72. The fan power of thecondenser fan76 and/orevaporator fan78 may be directly measured bysensors85 associated with thefans76,78 or may be estimated by theprocessing circuitry88.
• Once the non-measured operating parameters are determined, the performance of thecompressor10 andrefrigeration system11 can be determined by thedata module14. As noted above, thedata module14 may provide three levels of data to the diagnostics andcontrol module15. First, sensor data may be transmitted from thedata module14 to the diagnostics andcontrol module15 for use by the diagnostics andcontrol module15 in diagnosing and controlling thecompressor10 andrefrigeration system11. Second, the sensor data and/or non-measured operating parameters may be transmitted to the diagnostics andcontrol system15 for use by the diagnostics andcontrol module15 in diagnosing and controlling thecompressor10 and/orrefrigeration system11. Third, the sensor data, non-measured operating parameters, and compressor/refrigeration system diagnostics may be transmitted to the diagnostics andcontrol module15 for use by the diagnostics andcontrol module15 in diagnosing and controlling thecompressor10 and/orrefrigeration system11.
• Thedata module14 may include configuration data and fault history data stored therein in addition to the three tiers of data discussed above. Configuration data may include compressor serial number, manufacturing date, compressor performance maps, etc., while fault history data may include a list of faults previously experienced by the compressor and/or refrigeration system and a related cause of the particular fault. The configuration data and fault history data may be provided to the diagnostics andcontrol module15 to update the diagnostics andcontrol module15 or to configure a new diagnostics andcontrol module15 should the diagnostics andcontrol module15 require replacement. For example, if the diagnostics andcontrol module15 becomes faulty and a new diagnostics andcontrol module15 is installed, thedata module14 may provide the configuration and/or fault history data to the new diagnostics andcontrol module15 to configure the diagnostics andcontrol module15. Such configuration and fault history data may include data described in assignee's commonly-owned U.S. Provisional Patent Application No. 60/674,781 filed on Apr. 26, 2005 now U.S. patent application Ser. No. 11/405,021 filed on Apr. 14, 2006, the disclosures of which are herein incorporated by reference.
• With particular reference toFIGS. 8 and 9, operation of thedata module14 and diagnostics andcontrol module15 will be described in detail. As shown inFIG. 8, thedata module14 receives inputs from thevarious sensors80,82,84,86, which provide thedata module14 with current operating conditions of thecompressor10 and/orrefrigeration system11. Theprocessing circuitry88 of thedata module14 may use the data from therespective sensors80,82,84,86 to determine non-measured operating parameters of thecompressor10 and/orrefrigeration system11.
• As described above, thedata module14 may determine non-measured operating parameters of thecompressor10 and/orrefrigeration system11 such as subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature. For example, thedata module14 may receive liquid line temperature information from the liquidline temperature sensor84 and current and/or voltage information from thecurrent sensor80 and may use the information received from therespective sensors80,84 to determine the condenser temperature and subcooling (FIG. 4). Specifically, once the current drawn by the motor32 is known by information received fromcurrent sensor80, theprocessing circuitry88 ofdata module14 may reference the current reading from thecurrent sensor80 against a compressor map such as the plot shown inFIG. 5, which may be stored within thedata module14. Referencing the current drawn by the motor32 against a compressor map such as the plot shown inFIG. 5, yields an approximated condenser temperature by referencing the current drawn by the motor32 against an approximated evaporator temperature. Once the condenser temperature is determined by theprocessing circuitry88, the subcooling may then be determined simply by subtracting the liquid line temperature as measured by the liquidline temperature sensor84 from the determined condenser temperature, as indicated inFIG. 4.
• Once theprocessing circuitry88 of thedata module14 has determined the non-measured parameters of thecompressor10 and/orrefrigeration system11, thedata module14 may then transmit one or both of the sensor data received fromsensors80,82,84,86 and the derived, non-measured parameters to the diagnostics andcontrol module15. Theprocessing circuitry89 of the diagnostics andcontrol module15 may use the sensor data from thesensors80,82,84,86 and/or the derived, non-measured parameters to diagnose thecompressor10 and/orrefrigeration system11.
• Such diagnostics may be used to differentiate between various fault conditions of thecompressor10 and/orrefrigeration system11 and may be used to control/protect thecompressor10 and/orrefrigeration system11. For example, the diagnostics andcontrol module15 may use the received data from thedata module14 to control a capacity of thecompressor10. The diagnostics andcontrol module15 may modulate the compressor capacity by selectively separating theorbiting scroll member40 from thenon-orbiting scroll member48 via solenoid66, by selectively toggling the compressor between an ON state and an OFF state, and/or through blocked-suction modulation.
• In addition to simply transmitting the sensor data received fromsensors80,82,84,86 and the non-measured parameters to the diagnostics andcontrol module15, thedata module14 may also use the sensor data received fromsensors80,82,84,86 and/or the non-measured parameters to diagnose thecompressor10 and/orrefrigeration system11. Specifically, theprocessing circuitry88 of thedata module14 may use the sensor data received from thesensors80,82,84,86 and the non-measured parameters to provide the diagnostics andcontrol module15 with a diagnosis of thecompressor10 and/orrefrigeration system11.
• In addition to the foregoing, thedata module14 may alternatively provide a diagnosis of thecompressor10 and/orrefrigeration system11 directly to theprocessing circuitry89 of the diagnostics andcontrol module15 for use in directly controlling operation of thecompressor10 and/orrefrigeration system11.
• The diagnostics andcontrol module15 may use the diagnosis provided by thedata module14 for use in comparison to the diagnosis of thecompressor10 and/orrefrigeration system11 made by theprocessing circuitry89 of the diagnostics andcontrol module15. In this manner, the diagnostics andcontrol module15 is able to verify the diagnostics made by theprocessing circuitry89 by comparing the diagnostic made by theprocessing circuitry89 with that of theprocessing circuitry88.
• In addition to transmitting the sensor data fromsensors80,82,84,86, the non-measured operating parameters, and the diagnosis of thecompressor10 and/orrefrigeration system11 to the diagnostics andcontrol module15, thedata module14 may additionally or alternatively supply such sensor data, non-measured operating parameters, and/or diagnosis directly to an external system such as a computer orsystem controller104 and/or hand-helddevice106. The diagnostics andcontrol module15 may also supply thecomputer104 and/or hand-helddevice106 with the sensor data, non-measured operating parameters, and/or diagnosis received from thedata module14 as well as the diagnostics performed by the diagnostics andcontrol module15 for use by thecomputer104 and/or hand-helddevice106.
• Thecomputer104 and/or hand-helddevice106 may use the sensor data, non-measured operating parameters, and/or diagnosis to control, track and/or monitor operation of thecompressor10 and/orrefrigeration system11. For example, thecomputer104 may be remotely located from thecompressor10 and/orrefrigeration system11 such that thecompressor10 and/orrefrigeration system11 may be diagnosed, controlled, and monitored from a remote location. Providing a hand-helddevice106 with the sensor data, non-measured operating parameters, and/or diagnostics performed by thedata module14 and/or diagnostics andcontrol module15 provides a service technician with an operational history of acompressor10 and/orrefrigeration system11 for use in servicing thecompressor10 and/orrefrigeration system11.
• As shown inFIG. 8, thedata module14 and associatedprocessing circuitry88 may be separated from the diagnostics andcontrol module15 and associatedprocessing circuitry89. For example, thedata module14 and associatedprocessing circuitry88 may be positioned within theelectrical enclosure28 such that thedata module14 and associatedprocessing circuitry88 are mounted to theshell17 of thecompressor10 while the diagnostics andcontrol module15 and associatedprocessing circuitry89 are remotely located from thecompressor10. Remotely locating the diagnostics andcontrol module15 from thedata module14 allows for remote control of thecompressor10 and/orrefrigeration system11.
• While the diagnostics andcontrol module15 may be remotely located from thedata module14, the diagnostics andcontrol module15 may alternatively be received in theelectrical enclosure28 such that the diagnostics andcontrol module15 and associatedprocessing circuitry89 are mounted to theshell17 of thecompressor10.FIG. 2 shows thedata module14 and associatedprocessing circuitry88 as well as the diagnostics andcontrol module15 and associatedprocessing circuitry88 being disposed generally within theelectrical enclosure28 and mounted to theshell17 of thecompressor10.FIG. 10 schematically represents this relationship, whereby thedata module14 and diagnostics andcontrol module15 are integrated as a single unit. While thedata module14 and diagnostics andcontrol module15 are described as includingseparate processing circuitry88,89, respectively, when thedata module14 and diagnostics andcontrol module15 are incorporated into theelectrical enclosure28, thedata module14 and diagnostics andcontrol module15 may share processing circuitry.
• While thedata module14 and diagnostics andcontrol module15 may both be received within theelectrical enclosure28 of thecompressor10, separating the diagnostics andcontrol module15 from thedata module14, such that the diagnostics andcontrol module15 is remotely located from thedata module14 andcompressor10, allows thedata module14 to be used with various diagnostic and control modules. Because thedata module14 essentially serves as a hub for receiving sensor data and for determining non-measured operating parameters of a compressor and/or refrigeration system, thedata module14 may be used with virtually any diagnostics andcontrol module15.
• Original equipment manufacturers typically use different diagnostics and control modules and schemes. Therefore, adata module14 that may be interchanged and used with any diagnostics andcontrol module15 allows acompressor10 incorporating such adata module14 to be used with virtually any diagnostics andcontrol module15.
• Those skilled in the art may now appreciate from the foregoing that the broad teachings of the present disclosure may be implemented in a variety of forms. Therefore, while this disclosure has been described in connection with particular examples thereof, the true scope of the disclosure should no be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.

Claims (25)

1. A compressor comprising a shell, a compression mechanism, a motor, a data module, and a compressor controller, said data module including a processor and a memory, said compressor controller including a processor and a memory, said data module receiving sensed data, storing sensed data in said memory, and communicating sensed data to said compressor controller, said compressor controller controlling a capacity of the compressor based on said sensed data and operable to communicate with a system controller of a refrigeration system.

2. The compressor ofclaim 1, wherein said data module processor determines non-measured operating parameters of at least one of the compressor and said refrigeration system based on said sensed data.

3. The compressor ofclaim 2, wherein said non-measured operating parameters include subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature.

4. The compressor ofclaim 2, wherein said data module communicates said non-measured operating parameters to at least one of said system controller and said compressor controller.

5. The compressor ofclaim 2, wherein said data module diagnoses at least one of the compressor and said refrigeration system based on at least one of said sensed data and said non-measured operating parameters.

6. The compressor ofclaim 5, wherein said data module communicates said diagnosis to at least one of said system controller and said compressor controller.

7. The compressor ofclaim 1, wherein said data module diagnoses at least one of the compressor and said refrigeration system based on said sensed data.

8. The compressor ofclaim 7, wherein said data module communicates said diagnosis to at least one of said system controller and said compressor controller.

9. The compressor ofclaim 1, wherein said compressor controller diagnoses at least one of the compressor and said refrigeration system based on said sensed data from said data module.

10. The compressor ofclaim 9, wherein said compressor controller communicates said diagnosis to said system controller.

11. The compressor ofclaim 1, wherein said data module and said compressor controller are attached to the compressor.

12. For a refrigeration system including a system controller in communication with a compressor controller associated with a compressor, a data module comprising a housing, a processor and a memory, said housing mountable on the compressor, said processor receiving sensed data, storing sensed data in said memory, and operable to communicate sensed data to the compressor controller.

13. The data module ofclaim 12, wherein said data module processor determines non-measured operating parameters of at least one of said compressor and said refrigeration system based on said sensed data.

14. The compressor ofclaim 14, wherein said non-measured operating parameters include subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature.

15. The data module ofclaim 13, wherein said data module processor communicates said non-measured operating parameters to at least one of said system controller and said compressor controller.

16. The data module ofclaim 13, wherein said data module processor diagnoses at least one of said compressor and said refrigeration system based on at least one of said sensed data and said non-measured operating parameters.

17. The data module ofclaim 13, wherein said data module processor communicates said diagnosis to at least one of said system controller and said compressor controller.

18. The data module ofclaim 12, wherein said data module processor diagnoses at least one of said compressor and said refrigeration system based on said sensed data.

19. The data module ofclaim 18, wherein said data module processor communicates said diagnosis to at least one of said system controller and said compressor controller.

20. The data module ofclaim 12, wherein said compressor controller diagnoses at least one of said compressor and said refrigeration system based on said sensed data from said data module processor.

21. The data module ofclaim 20, wherein said compressor controller communicates said diagnosis to said system controller.

22. A compressor control system comprising:

a compressor;

a compressor controller operable to diagnose and/or control said compressor; and

a data module associated with said compressor and in communication with said compressor controller, said data module receiving sensor data indicative of compressor performance, determining non-measured system operating parameters, and diagnosing said compressor based on at least one of said sensor data and said non-measured system operating parameters, said data module communicating said sensor data, said non-measured system operating parameters, and said diagnosis to said compressor controller.

23. The compressor ofclaim 22, wherein said compressor controller determines said non-measured system operating parameters based on said received sensor data and diagnoses said compressor based on at least one of said received sensor data and said determined non-measured system operating parameters, said compressor controller comparing said determined non-measured system operating parameters to said non-measured system operating parameters received from said data module and comparing said determined diagnosis to said diagnosis received from said data module.

24. A method comprising:

communicating sensor data to a data module;

processing said sensor data at said data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system;

processing at least one of said sensor data and said determined non-measured operating parameters at said data module to diagnose said at least one compressor and refrigeration system;

communicating said sensor data, said non-measured operating parameters, and said diagnosis to a system controller;

determining said non-measured operating parameters at said system controller based on said received sensor data;

determining said diagnosis at said system controller based on said received sensor data and said determined non-measured operating parameters;

comparing said received non-measured operating parameters to said determined non-measured operating parameters at said system controller; and

comparing said received diagnosis to said determined diagnosis at said system controller.

25. A method comprising:

communicating sensor data to a data module;

processing said sensor data at said data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system;

processing at least one of said sensor data and said non-measured operating parameters at said data module to diagnose said at least one compressor and refrigeration system;

storing at least one of said sensor data, said non-measured operating parameters, and said diagnosis in a memory of said data module;

communicating at least one of said sensor data, said non-measured operating parameters, and said diagnosis to a first system controller;

replacing said first system controller with a second system controller; and

communicating at least one of said stored sensor data, said stored non-measured operating parameters, and said stored diagnosis to said second controller.

Images