KR101922958B1 - System and method of controlling a variable-capacity compressor - Google Patents

Abstract

The climate control system may include a variable capacity compressor unit and a control module for controlling the compressor unit. The compressor unit is operable in a first capacity mode and a second capacity mode higher than the first capacity mode. The control module may be configured to switch the compressor unit between an operation stop state, a first capacity mode and a second capacity mode based on a demand signal and outdoor air temperature data.

Description

SYSTEM AND METHOD OF CONTROLLING A VARIABLE-CAPACITY COMPRESSOR [0002]

The present invention relates to a climate control system having a variable capacity compressor.

This identification item provides background information relating to the present invention and is not necessarily the prior art.

For example, a climate control system, such as a heat pump system, a refrigeration system or an air conditioning system, may be used to control the operation of the outdoor heat exchanger, the indoor heat exchanger, the expansion device disposed between the outdoor heat exchangers, , Refrigerant, i.e., carbon dioxide). By changing the capacity of the compressor, the energy efficiency of the system and the speed with which the system can heat or cool the room or space can be affected.

U.S. Published Patent Application No. 2007-0227167 A1 (published on October 4, 2007)

This identification provides a general overview of the invention and is not a comprehensive disclosure of its full scope or all of its features.

In one aspect, the present invention provides a climate control system including a variable capacity compressor unit and a control module for controlling the compressor unit. The compressor unit is operable in a first capacity mode and a second capacity mode higher than the first capacity mode. The control module may be configured to switch the compressor unit between an operation stop state, a first capacity mode and a second capacity mode based on a demand signal and outdoor air temperature data. The control module may include an outdoor air temperature sensing and a demand signal sensing circuit.

In some embodiments, the control module receives a request signal from a single-stage thermostat disposed within a space to be cooled by the climate control system.

In some embodiments, the climate control system may include an indoor heat exchanger that receives the working fluid from the compressor unit, and an air blower that forcibly blows air to establish a convective heat transfer relationship with the working fluid in the indoor heat exchanger. The blower may comprise, for example, a fixed speed motor or a variable speed motor operable at a selectable fixed speed tap.

In some embodiments, the control module switches the compressor unit between the first mode and the second mode based on the compressor operating time.

In some embodiments, the compressor operating time is the operating time of the compressor unit in the second capacity mode.

In some embodiments, the operating time of the compressor unit in the second capacity mode is the same as the operating time in the previous second capacity mode during the previous demand period. That is, the operation time of the compressor unit in the second capacity mode can be appropriately compared with the operation time in the previous second capacity mode every cycle.

In some embodiments, the control module switches the compressor unit from the first capacity mode to the second capacity mode based on whether the previous operating time was longer than 5 minutes.

In some embodiments, the control module controls the compressor unit from a first capacity mode to a second capacity mode based on whether the compressor unit is operating in a first capacity mode for longer than a predetermined period of time, .

In some embodiments, the climate control system includes a comfort control interface configured to be located at one of a plurality of comfort level settings. The first set value of the comfort level set values may correspond to the energy efficiency operation mode, and the second set value of the comfort level set values may correspond to the high performance operation mode.

In some embodiments, the control module is configured to compare the compressor operating time with a low capacity operating time threshold and a high capacity operating time threshold.

In some embodiments, the control module controls the compressor in a low capacity mode and a high capacity mode based on a comparison with the first capacity operation time of the compressor operation time and a comparison with the second capacity operation time of the compressor operation time As shown in Fig.

In some embodiments, the low-capacity operation time threshold and the high-capacity operation time threshold are determined based on a selected one of the plurality of comfort level set values.

In some embodiments, the control module operates the compressor unit in one of the first capacity mode and the second capacity mode based on the request signal, the outdoor air temperature data, and at least one compressor operating time.

In some embodiments, the at least one compressor operating time is the operating time of the compressor unit in the second mode of operation.

In some embodiments, the compressor unit includes only one compressor (e.g., a variable capacity compressor). In another embodiment, the compressor unit may comprise a plurality of variable capacity and / or fixed capacity compressors.

In yet another aspect, the present invention provides a method of controlling a compressor operable in a first capacity mode and a second capacity mode higher than the first capacity mode. The method comprises the steps of receiving a request signal from a thermostat; Setting a low-capacity operation time threshold value based on the user-selected comfort level; Operating the compressor in a low capacity mode in response to receipt of the request signal; Comparing the operation time of the compressor with the low-capacity operation time threshold value; And switching the compressor from the low capacity mode to the high capacity mode based on a comparison between the operation time and the low capacity operation time threshold value.

In some embodiments, the method includes setting a usage time threshold based on a user selected comfort level.

In some embodiments, the method includes switching the compressor from a high capacity mode to a low capacity mode based on a comparison of the operating time and the high capacity operating time threshold.

In yet another aspect, the present invention provides a method of controlling a compressor. The compressor is operable in a first capacity mode and a second capacity mode that is higher than the first capacity mode. The method includes receiving a request signal from a thermostat; Comparing the outdoor air temperature with a predetermined temperature value; Comparing the operation time of the compressor with a predetermined operation time value; And comparing the outdoor air temperature with the predetermined temperature value and comparing the operation time with the predetermined operation time value in response to the reception of the request signal, And operating the compressor.

In some embodiments, the method further comprises: when the outdoor air temperature is lower than the predetermined temperature value and when the total operating time of the compressor since receipt of the request signal is less than the predetermined operating time value, And operating the compressor only in the first capacity mode until the request is satisfied.

In some embodiments, the method includes switching the compressor from the first mode of operation to the second mode of operation based on a comparison between the operating time and the predetermined operating time value.

In some embodiments, the method further comprises activating the compressor in a first mode of operation until the operating time exceeds the predetermined operating time value, and after the operating time exceeds the predetermined operating time value And switching the compressor from the first capacity mode.

In some embodiments, the predetermined operating time value is a previous amount of time that the compressor previously operated in the second capacity mode from the start of the second capacity mode until the satisfaction of the previous request signal.

In some embodiments, the compressor is operated in one of a first capacity mode and a second capacity mode based on the demand signal, the outdoor air temperature data, and at least one compressor operating time.

In another aspect, the present invention provides a working fluid circuit that may include an indoor heat exchanger and an outdoor heat exchanger, an expansion device, a variable displacement compressor, and a control module. The outdoor heat exchanger may be in fluid communication with the indoor heat exchanger. The expansion device may be disposed between the indoor heat exchanger and the outdoor heat exchanger. The variable displacement compressor can circulate the working fluid between the indoor heat exchanger and the outdoor heat exchanger. The control module controls the compressor and can operate the compressor in one of the low capacity mode and the high capacity mode based on the request signal, the outdoor air temperature data, and the compressor operation time.

In some embodiments, the working fluid circuit is in communication with the control module and comprises a first thermostat configured to generate the request signal. The request signal is typical for operation in the first and second capacitive modes.

In some embodiments, the working fluid circuit includes an indoor blower configured to forcibly blow air in a convective heat transfer relationship with the indoor heat exchanger.

In some embodiments, the control module switches the compressor between a first mode of operation and a second mode of operation based on another compressor operating time.

In some embodiments, the working fluid circuit includes a comfort control interface configured to be located in one of a plurality of comfort level settings. The first set value of the comfort level set values may correspond to the energy efficiency operation mode, and the second set value of the comfort level set values may correspond to the high performance operation mode.

In some embodiments, the control module is configured to compare the compressor operating time with a first capacity operating time threshold and a second capacity operating time threshold.

In some embodiments, the control module is configured to cause the compressor to operate in a first capacity mode and a second capacity mode based on a comparison with a first capacity operation time of the compressor operation time and with a second capacity operation time of the compressor operation time And to switch between the second capacity modes.

In some embodiments, the first capacity operating time threshold and the second capacity operating time threshold are determined based on a selected one of the plurality of comfort level setting values.

Additional applicable fields will become apparent from the description provided herein. The description of this outline section and specific embodiments are intended for illustrative purposes only and are not intended to limit the scope of the invention.

The drawings briefly described herein are for illustration of selected embodiments only and are not intended to limit the scope of the invention.
1 is a schematic diagram of a heat pump system having a variable displacement compressor in accordance with the principles of the present invention.
2 is a state diagram illustrating a method and an algorithm for controlling the variable capacity compressor of FIG.
3 is a graph showing the relationship between the low capacity level and the high capacity level of the compressor for the exemplary climate control system sized for an exemplary climate of an exemplary climate, the heat load of the house and the outdoor temperature.
4 is a graph showing the operating time percentage of the low-capacity mode and the high-capacity mode for a certain range of outdoor air temperature.
5 is a state diagram illustrating another method and algorithm for controlling the variable capacity compressor of FIG.
Figure 6 is a look-up table that includes a given comfort level and a low capacity operating time threshold for a given outdoor outdoor temperature.
7 is a look-up table that includes a given comfort level and a high capacity operating time threshold for a given outdoor outdoor temperature.
8 is a graph showing a low capacity operation time and a high capacity operation time at the time of operation at the first comfort level.
9 is a graph showing a low-capacity operation time and a high-capacity operation time at the time of operation at the second comfort level.
10 is a graph showing a low-capacity operation time and a high-capacity operation time at the time of operation at the third comfort level.
11 is a schematic diagram of a comfort control interface and control module.
Corresponding reference characters throughout the several views indicate corresponding parts.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Exemplary embodiments will now be described in detail with reference to the accompanying drawings.

Illustrative embodiments are provided so that the invention may be fully understood and communicated to those skilled in the art. A number of specific embodiments, such as embodiments of specific components, devices, and methods, are provided to provide a thorough understanding of embodiments of the present invention. It will be apparent to those skilled in the art that the specific embodiments need not necessarily be employed for the present invention and that the exemplary embodiments may be embodied in many different forms and should not be construed as limiting the scope of the present invention. In some embodiments, known processes, known device structures, and known techniques are not described in detail.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, " singular " is intended to include plural forms, unless the context clearly dictates otherwise. The terms "comprises", "comprising" and "having" are intended to be inclusive and thus indicate the presence of stated features, integers, steps, operations, elements and / But does not preclude the presence or addition of other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring the practice of the specific sequence illustrated unless the order of execution is specifically indicated. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to simply as being "above," "coupled to", "connected to", or "coupled to" another element or layer, , Any element or layer may be directly on (directly on the surface), directly (directly) coupled, directly (directly) connected, or directly (directly) coupled to another element or layer It can encompass any intervening elements or layers. On the other hand, when an element is referred to as being "directly on the surface", "directly connected to", "directly connected to", or " Quot; directly coupled " to " coupled to (directly) coupled to " means that there are no intervening elements or layers. Other expressions used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" and "immediately", "adjacent" and "immediately adjacent", etc.). As used herein, the term "and / or" includes one or more than one combination of each of the listed items.

It should be understood that although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / It should not be limited by terms such as first, second, third, etc. The terms first, second, third, etc. may be used only to distinguish one element, element, region, layer or region from another. "First," " second, " and other numerical terms, when used herein, do not denote a sequence or order unless specifically indicated in the context. Thus, the first element, the first element, the first region, the first layer, or the first region, which will be described below, will be referred to as a second element, a second element, a second region, Layer or a second zone.

Relative terms on the space such as "inner (inner)," " outer (outer), " Or other element or feature of the feature of the present invention. Relative terms in space may be intended to encompass not only the orientation shown in the figures but also other orientations in use or operation. For example, if an apparatus in the drawing is to be turned upside down, the elements described as "below" or "directly below" another element or feature will now be oriented "above" another element or feature. Thus, for example, the term "below" can encompass all orientations above and below. The device may be oriented differently (90 degree rotational orientation or other orientation), and the spatial relative terms used herein may be interpreted accordingly.

1, a variable capacity compressor (or a variable capacity compressor group) 12, an outdoor heat exchanger 14, an outdoor blower 15, a first expansion device 16, a second expansion device 17, A heat exchanger 18, and a room air blower 19. In the system 10, 1, the system 10 includes a switching valve 20 operable to control the direction of the working fluid flow through the system 10 to switch the system 10 between a heating mode and a cooling mode, Gt; 10 < / RTI > In some configurations, the system 10 may be, for example, an air conditioning system or a refrigeration system, and may only operate in cooling mode. The control module 22 may control the operation of the compressor 12 and may receive data received from the outdoor air temperature sensor 24, a signal received from the thermostat 26, Based on the comparison between the operation time T of the compressor 12 and the predetermined low capacity operation time threshold value T1 and the comparison between the previous high capacity operation time threshold value T2 and the predetermined value, It can be switched between the low capacity mode and the high capacity mode. The control module 22 may minimize or reduce the use of high capacity mode operation to minimize or reduce energy usage while maintaining an acceptable level of comfort within the space to be heated or cooled.

The compressor 12 may be, for example, a scroll compressor, a reciprocating compressor, a rotary vane compressor, and / or other types of compressors. Compressor 12 may be any type of variable displacement compressor capable of operating in at least a low capacity mode and a high capacity mode. For example, the compressor 12 may be a multi-stage compressor, a group of independently operable compressors, a multi-stage or variable speed compressor (with a variable speed or multi-stage speed motor), a modulated suction (E. G., A digital scroll compressor) configured for scroll separation, a compressor with a variable volume ratio valve configured to leak an intermediate pressure working fluid, or a compressor with a variable volume ratio valve configured to < RTI ID = A compressor having two or more of the above-mentioned capacity modulation means, or the like. It will be appreciated that the compressor 12 may include any other additional or alternative structure for changing its capacity and / or operating capacity of the system 10. It will be appreciated that the high capacity mode and / or high capacity mode may be a continuous steady state operating mode, or the compressor 12 may be modulated (e.g., pulse width modulated) during operation of the low capacity mode and / will be. Exemplary variable displacement compressors are described in U.S. Patent Nos. 8,616,014, 6,679,072, 8,585,382, 6,213,731, 8,485,789, 8,485,789, 8,459,053, and U.S. Patent No. 5,385,453.

The compressor 12, the outdoor heat exchanger 14, the outdoor blower 15, the first expansion device 16, and the switching valve 20 may be disposed in the outdoor unit 28. The second expansion device 17, the indoor heat exchanger 18 and the indoor blower 19 are connected to an indoor unit 30 (for example, an air handler or air an air furnace). A first check valve 34 may be disposed between the outdoor heat exchanger 14 and the first expansion device 16 to limit or prevent fluid flow through the first expansion device 16 in the cooling mode , Allowing fluid flow through the first expansion device 16 in the heating mode. A second check valve 36 may be disposed between the second expansion device 17 and the indoor heat exchanger 18 to limit or prevent fluid flow through the second expansion device 17 in the heating mode, Mode to allow fluid flow through the second expansion device 17.

The outdoor air temperature sensor 24 is disposed inside or outside the outdoor unit 28 outside the building 32 and measures the outdoor outdoor air temperature and outputs the outdoor air temperature value intermittently, . In some configurations, the outdoor air temperature sensor 24 may be a thermostat or other sensor that is associated with or is an entity of a climate monitoring and / or climate reporting system. In such an arrangement, the control module 22 may control the outdoor temperature (as measured by the sensor 24) from the climate monitoring and / or climate reporting system or entity, such as via the Internet, Wi-Fi, Bluetooth®, Zigbee®, PLCC, or cellular connectivity, or any other wired or wireless communication protocol. For example, the control module 22 may communicate with the climate monitoring and / or weather reporting system or entity over the Internet via a Wi-Fi connection to a Wi-Fi router associated with the building in the building. The thermostat 26 is arranged outside the indoor unit 30 inside the building 32 and is configured to measure the temperature of the air in the room or space to be cooled or heated by the system 10. The thermostat 26 generates only one type of request signal in response to temperature in the room or space (e.g., in a heating mode) that rises above the setpoint temperature or falls below the setpoint temperature (in cooling mode) And may be a single-stage thermostat. The control module 22 may be disposed, for example, at any suitable location inside or adjacent to the outdoor unit 28 or inside or adjacent to the indoor unit 30. [

In the cooling mode, the outdoor heat exchanger 14 can operate as a condenser or gas cooler, and for example, conveys heat from the working fluid to the air forced to blow over the outdoor heat exchanger 14 by the outdoor blower 15 The discharge pressure working fluid received from the compressor 12 can be cooled. The outdoor blower 15 may include a fixed speed, multi-speed or variable speed fan. In the cooling mode, the indoor heat exchanger 18 is connected to an evaporator (not shown) that absorbs heat from the air forced to be blown onto the indoor heat exchanger 18 by the indoor blower 19 to cool the space in the house or the building 32 Lt; / RTI > The indoor blower 19 may comprise a fixed speed, multi-speed or variable speed fan. In the heating mode, the outdoor heat exchanger 14 operates as an evaporator, the indoor heat exchanger 18 can operate as a condenser or gas cooler, and the heat from the working fluid discharged from the compressor 12 is converted into a space to be heated .

Referring to Figures 1 and 2, the method and control algorithm 100 of the control module 22 is described. The algorithm 100 may control the operation of the compressor 12 and may switch the compressor 12 between a low capacity mode and a high capacity mode. In the initial state 110, the compressor 12 may be turned off. The thermostat 26 responds to the air temperature in the space to be heated or cooled by the system 10 (in cooling mode) that falls below the selected set point temperature (in the heating mode) or exceeds the selected set point temperature The request signal Y can be transmitted to the control module 22. [ In response to receipt of the request signal Y, the control module 22 may initiate operation of the compressor 12 in the low capacity mode (state 120). Initiation of operation of the compressor 12 in the low capacity mode may reduce or minimize the energy rush-in and mechanical stress upon start-up of the compressor 12.

The control module 22 can receive the outdoor outdoor temperature measured by the sensor 24 (input 130), and when the system 10 is in the cooling mode, the outdoor outdoor temperature is the first predetermined temperature value (For example, 90 degrees Fahrenheit or the like). If the outdoor outside air temperature is lower than the first predetermined temperature value, the control module 22 determines whether the temperature in the space to be cooled is equal to or higher than the predetermined set point temperature Or until the total operating time T of the compressor 12 since the receipt of the request signal Y is less than a predetermined time T Until the compressor 12 or system 10 is manually shut down or the diagnostic or protection algorithm overrides the algorithm 100 until the compressor 12 or system 10 is shut down or the diagnostic or protection algorithm overrides the algorithm 100, The compressor can be operated in the low capacity mode (state 120). The predetermined low capacity operation time T1 may be, for example, approximately 40 minutes. The control module 22 may cause the compressor 12 to shut down (state 140) if the demand is met before the total operating time T reaches a predetermined low capacity operating time T1. The first predetermined temperature value may be selected to minimize the operating time in the high capacity mode in a majority or majority of the houses or buildings in multiple or most of the climatic conditions for one or more geographic locations. The predetermined low capacity operating time T1 prevents premature switching to the high and / or high capacity mode (which uses more energy than desired) to avoid operating in the low capacity mode longer than desired for comfort Lt; / RTI > In some embodiments, and in some situations also, the compressor 12 is configured to provide a majority (e.g., 80% or more) of the cooling seasons (e.g., summer) for many or most of the houses or buildings in many or most of the climate or geographic area ) In the low-capacity mode.

The control module 22 changes the compressor 12 from the low capacity mode to the high capacity mode (state 150) if the compressor 12 is operated longer than the predetermined low capacity operation time T1 without satisfying the requirement Can be switched. The compressor 12 continues to operate in a high capacity mode until the cooling demand is met (or until the compressor 12 or system 10 is manually shut down or a diagnostic or protection algorithm overrides the algorithm 100) . ≪ / RTI > When the demand is met, the control module 22 may shut down the compressor 12 (state 140) instead of switching back to the low capacity mode. The control module 22 records the operation time T2 of the compressor 12 in the high capacity mode when the compressor 12 is stopped after satisfying the requirement by operating in the high capacity mode, ) To a memory module (not shown) associated with the control module 22.

If the control module 22 determines that the outdoor outdoor air temperature is equal to or higher than the first predetermined temperature value after the compressor 12 is initially started in the low capacity mode in response to the initial reception of the request signal Y, May wait (state 160) to allow the compressor 12 to continue operating in a low capacity mode for a predetermined waiting period (e.g., about 5 seconds). The predetermined waiting period may be selected to ensure a stable start of the compressor 12 in a state that does not significantly affect the performance of the system to control overall system capacity and / or comfort. After the predetermined waiting period has ended, the control module 22 determines whether the last operating time T2 of the compressor 12 in the high capacity mode has exceeded a predetermined time period (e.g., 5 minutes) (state 170) Can be determined. This predetermined time period may be determined by whether the thermal load of the house or building 32 is sufficiently high to be desired to achieve the desired comfort or need to switch to the high capacity mode or continue operation of the low capacity mode to still achieve the desired comfort control Lt; RTI ID = 0.0 > low < / RTI > The control module 22 may switch the compressor 12 from the low capacity mode (state 120) to the high capacity mode (state 150) if the last high capacity operation time T2 was greater than the predetermined time period. The compressor 12 may then continue until the cooling demand is met (or until the compressor 12 or system 10 is manually shut down or a diagnostic or protection algorithm overrides the algorithm 100) , And can be continuously operated in the high capacity mode. When the cooling demand is met, the control module 22 may shut down the compressor 12 (state 140).

If the last high capacity operation time T2 was less than the predetermined time period in state 170, the control module 22 determines whether the cooling demand is satisfied or the compressor 12 The compressor 12 is continuously operated in the low capacity mode (state 120) until the total operation time T exceeds the predetermined low capacity operation time T1 or until the algorithm 100 is overridden .

Algorithm 100 may be used to determine whether the outdoor air temperature is below a second predetermined temperature value, when the system 10 is in the heating mode, May operate similar or identical to those described above. The second predetermined temperature value when the system 10 is in the heating mode may be different from the first predetermined temperature value in the cooling mode. For example, the second predetermined temperature value in the heating mode may be about 40 degrees Fahrenheit. Accordingly, in the heating mode, when the control module 22 determines that the outdoor outdoor air temperature exceeds the second predetermined temperature value, the control module 22 determines whether the outdoor air temperature exceeds the second predetermined temperature value, The compressor 12 can be continuously operated in the low capacity mode (state 120) until the predetermined low capacity operation time T1 is exceeded, or until the algorithm 100 is overridden. In the heating mode, the algorithm 100 may enter the state 160 if the control module 22 determines that the outdoor outdoor air temperature is below the second predetermined temperature value. From state 160, it may operate similar or identical to that described above for the cooling mode. For many homes or buildings, the operation of the low capacity mode in the heating mode may be sufficient to meet the heating needs while the outdoor air temperature is above 40 degrees Fahrenheit, and the high capacity mode operation Is intended to be either unnecessary or undesirable.

Below a third predetermined outdoor air temperature (e.g., 20 degrees Fahrenheit), even when multiple heat pump systems operate continuously in a high capacity mode, they can not have sufficient capacity to meet the heating needs. Thus, an alternative or supplemental heating system may be used instead of or in addition to such a heat pump system. Below this third predetermined temperature, before activating the alternative or supplemental heating system, the control module 22 causes the compressor 12 to operate in a high capacity mode for a third predetermined operating time (e.g., 30 minutes) can do.

The variable capacity compressor 12, the control module 22 and the algorithm 100 can operate together with the indoor unit 30 once the thermostat 26 and the fixed speed blower 19, as described above. Thus, the control module 22 and algorithm 100 of the present invention can be implemented in a conventional climate control system with fixed capacity, without modifying the system to include an indoor unit with a multi-stage thermostat and / Capacity compressor 12 and the control module 22, as shown in FIG. Modifying the fixed capacity climate control system to include the variable capacity compressor 12 and the control module 22 without having to replace the thermostat 26 and the fixed speed blower 19 would require the climate control system to be in a multi- And / or an indoor unit having a multi-stage speed blower, without the added significant cost and complexity associated with retrofitting. Alternatively, if only the multistage thermostat is connected to transmit a single request signal (e.g., both the low capacity demand wire and the high capacity demand wire connected to the compressor 12 and / or the control module 22) , Only one request wire is connected to the compressor 12 and / or the control module 22), a multi-stage thermostat may be employed.

The predetermined first and second predetermined temperature values, the predetermined low capacity operation time (T1), the predetermined waiting period and / or the predetermined time period may be determined based on the climate, the geographical location, the compressor 12) and / or the system is operating in the cooling mode or in the heating mode.

In some embodiments, the outdoor air temperature used in the algorithm 100 may not necessarily be an instantaneous or real time temperature value. Alternatively, the control module 22 may obtain or determine an average outdoor air temperature over previous operating cycles or over specific time periods that account for the solar radiation and / or heat capacity of the building 32 or space to be heated or cooled have.

In some embodiments in which the control module 22 receives outdoor air temperature from a remote climate report and / or weather forecast database or source, the control module 22 determines the high capacity mode operating history of the date versus the outdoor air temperature history and the time As shown in FIG. In this embodiment, the control module 22 is configured to predict the expected future date and time to be switched to the high capacity mode based on the predicted outdoor air temperature and the recorded history of the operating history versus the outdoor air temperature history and time .

FIG. 3 is a graph showing the capacities of an exemplary variable capacity compressor in the low capacity mode and the high capacity mode at various outdoor air temperatures and the thermal load of an exemplary house at various outdoor air temperatures. 4 is a graph showing the percentage of the compressor operating time in the low capacity mode and the high capacity mode. When the outdoor air temperature is within a range where the thermal load of the house is smaller than the compressor capacity in the low capacity mode, the control module 22 can only operate the compressor in the low capacity mode. When the outdoor air temperature is within a range in which the thermal load of the house is higher than the compressor capacity in the low capacity mode and lower than the compressor capacity in the high capacity mode, the control module 22 controls the compressor between the low capacity mode and the high capacity mode Can be switched. When the outdoor air temperature is within a range where the thermal load of the house is higher than the capacity of the compressor in the high capacity mode, the control module 22 can operate the compressor in a high capacity mode exclusively or almost exclusively.

The percent operating time shown in Fig. 4 can be derived as the ratio of the thermal load of the house to the unit capacity of each capacity stage at the given outdoor air temperature shown in Fig. Based on the experiment, a predetermined operating time T1 (e.g., 40 minutes) may be selected to represent the maximum operating time in a preferred or acceptable low-capacity mode before it is desired to switch to the high-capacity mode. The predetermined operation time T1 may be changed according to the relative capacity of the compressor in the low capacity mode and the high capacity mode with respect to the thermal load of the house. FIG. 3 is based on a sizing rule where the high capacity mode at ambient temperature of 95 degrees is about 10% higher than the thermal load of the house. The predetermined ambient temperature at which the high capacity stage begins to operate may be in the range of 85 to 90 degrees Fahrenheit.

Referring to Figures 1 and 5-11, another control module 22 method and control algorithm 100 is described. The algorithm 200 may control the operation of the compressor 12 and may switch the compressor 12 between a low capacity mode and a high capacity mode. In the initial state 210, the compressor 12 may be turned off. The thermostat 26 responds to the air temperature in the space to be heated or cooled by the system 10 (in cooling mode) that falls below the selected set point temperature (in the heating mode) or exceeds the selected set point temperature The request signal Y can be transmitted to the control module 22. [ In response to receiving the request signal Y, the control module 22 may initiate operation of the compressor 12 in the low capacity mode (state 220). As described above, when the operation of the compressor 12 is started in the low-capacity mode, energy rush-in and mechanical stress can be reduced or minimized at the start-up of the compressor 12.

After receipt of the request signal Y, the control module 22 may determine whether to start the compressor 12 before the initial startup of the compressor 12 in state 220, or at the same time as the initial startup of the compressor 12 in state 220, The low capacity operation time threshold value T1 'and the high capacity operation time threshold value T2' can be determined and set after the initial start of the compressor 12 in the state 220. In state 230, the control module 22 may determine the operating time thresholds T1 ', T2' based on the outdoor outdoor temperature (input 234) and the comfort level selection (input 232) . As described above, the outdoor outdoor air temperature can be received from the outdoor air temperature sensor 24. The comfort level selection may be received from a comfort control interface 225 (Figure 11) in communication with the control module 22

In some configurations, the comfort control interface 225 may include, for example, a dial 227 that is movable between a plurality of positions. 11, the dial 227 is movable between five different positions, each corresponding to a different one of the comfort levels 1-5 (labeled 229 in FIG. 11) Do. The comfort control interface 225 may communicate with the control module 22 via a wired or wireless connection. For example, the comfort control interface 225 may be controlled by a control module (not shown) via an Internet connection (wired or wireless), a cellular connection, a Bluetooth connection, a radio frequency signal, an infrared signal and / The user control interface 225 may include one or more buttons, switches, and / or a touch screen interface instead of or in addition to the dial 227. In some configurations, Control interface 225 may include thermostat 26 or be part of thermostat 26 and may be a computer, smartphone, tablet or any other computing, control and / or communication device.

The comfort control interface 225 enables the user to adjust the low capacity and high capacity operating time thresholds T1 ', T2' to regulate the energy efficiency and performance of the system 10. In the configuration illustrated in the figures comfort level 1 reduces the amount of time the compressor 12 can be operated in a high capacity mode and increases the amount of time the compressor 12 can operate in the low capacity mode , And a set value for increasing the energy efficiency of the system 10. [ Comfort level 5 increases the amount of time the compressor 12 can be operated in a high capacity mode and increases the performance of the system 10 by decreasing the amount of time the compressor 12 can operate in the low capacity mode (I. E., Increasing the ability of the system 10 to cool or heat the space more rapidly).

Figures 6 and 7 illustrate an exemplary embodiment of a system for providing an exemplary low capacity operating time threshold and a high capacity operating time threshold (T1 ', T2') for a given outdoor outdoor temperature (range of temperatures) for each of five comfort levels 1 and second search tables 231 and 233, respectively. The values of the lookup tables 231 and 233 may be stored in a memory unit and / or in a computer, tablet, smartphone, handheld device, cloud (i.e., Internet connection server) and / or control module 22 associated with the control module 22 May be stored in a memory unit associated with any suitable operation and / or memory device that may be configured to communicate. As shown in FIGS. 6 and 7, for each given outdoor outdoor temperature, the low capacity operation time threshold T1 'decreases as the comfort level increases from comfort level 1 to comfort level 5, The high-capacity operation time threshold value T2 'increases as the comfort level increases from the comfort level 1 to the comfort level 5. The exemplary look-up tables 231, 233 shown in Figures 6 and 7 are used while the system 10 is operating in the cooling mode. An additional table (not shown) may be stored in the memory unit of the control module 22 for use in the heating mode. These additional tables may contain values that are different from those provided in tables 231 and 233.

In state 230, the control module 22 determines the comfort level selection received at the input 232 based on the outdoor ambient air temperature received at the input 234 and the tables 231, 233, The thresholds T1 ', T2' can be determined. Next, in states 236 and 238, the control module 22 may set the thresholds T1 ', T2' to the values determined in state 230, respectively. It will be appreciated that the control module 22 may apply a formula or series of operations to determine the run time thresholds T1 ', T2' instead of referencing the lookup tables 231, 233.

The compressor 12 is operated by the compressor 12 until the total operation time T of the compressor 12 has reached the low capacity operation time set in the state 236 as long as the request signal Y is on and the initial operation of the compressor 12 since the initial reception of the request signal Y Can be continuously operated in the low capacity mode (state 220) as long as it is less than the threshold value T1 '. When the request signal Y is off, the control module 22 can shut down the compressor 12 in state 240. If the total operating time T exceeds the low capacity operating time threshold T1 ', the control module 22 resets the total operating time T to 0 (state 250) To the high capacity mode (state 260). The compressor 12 continues to operate in the high capacity mode (state 260) as long as the request signal Y is on and the overall operation time T is less than the high capacity operation time threshold T2 'set in state 238. [ ). ≪ / RTI > The control module 22 resets the total operating time T to 0 (state 270), and the algorithm 200 resets the total operating time T to zero (state 270) if the total operating time T exceeds the high capacity operating time threshold T2 ' May return to state 230 to determine and set the low capacity and high capacity operating time thresholds T1 ', T2' before returning the compressor 12 to the low capacity mode at state 220. [ Thereafter, the algorithm 200 continues until the request signal Y is turned off or until the operation of the compressor 12 is overridden (e.g., when manually overridden or overridden by the compressor protection routine) To repeat some or all of the steps described above.

8-10 show the operating times of the compressor 12 in the low capacity and high capacity modes for various comfort levels. FIG. 8 shows a low capacity and a high capacity operation time for a low comfort level (for example, comfort level 1). 9 shows low capacity and high capacity operation time for the intermediate comfort level (e.g., comfort level 3). Fig. 10 shows a low capacity and a high capacity operation time for a high comfort level (e.g., comfort level 5). As shown in FIGS. 8-10, a higher comfort level setting allows the compressor 12 to operate longer in a high capacity mode, which improves the performance of the system 10. A lower comfort level setting allows the compressor 12 to operate in a lower capacity mode for a longer time, which improves the energy efficiency of the system 10 by reducing power consumption. As shown in Figs. 8-10, the operating time in the low capacity mode decreases as the comfort level increases.

It will be appreciated that the comfort level may be changed at any point in the algorithm 200 and that the low capacity and high capacity operating time thresholds T1 ', T2' may be updated immediately in response to a change in comfort level .

In some arrangements, the control module 22 may adjust the operating time thresholds T1 ', T2' based on, for example, weather forecasts such as humidity, cloudiness and / or precipitation and / have. In some arrangements, the control module 22 may increase the low capacity operating time threshold T1 'for a given comfort level and / or increase the low capacity operating time threshold T1' for a given comfort level if the current climate conditions include low humidity, Or the high-capacity operation time threshold value T2 '. In some configurations, the control module 22 may adjust the values of the tables 231, 233 based on the climate of the particular geographic area in which the system 10 is installed (or use other tables for the algorithm 200) have). For example, the comfort control interface 225 or thermostat 26 may be configured to allow a user or installer to enter a geographic area or climate type in which the system 10 is installed. In some arrangements, the control module 22 may adjust the values of the tables 231, 233 based on historical data such as previous operating times, previous outdoor air temperatures, and / or other previous climatic conditions. In some configurations, the values in tables 231 and 233 may be adjusted based on the current or predicted future energy costs. In some configurations, the reference setting of values for tables 231, 233 may be stored in the memory unit for future use.

In some configurations, the comfort level may be a parameter set by the installer or service provider at the time of installation of the system 10 or at the service of the system 10. [ In some such configurations, the comfort level selection can not be easily adjusted by the homeowner and / or a resident of a home or building. In some configurations, the electric utility company or group has the ability to set and adjust comfort level selections and / or the ability to aurora comfort level choices made by, for example, a home owner and / or a home or building occupant . In such an arrangement, a comfort level can be selected which uses a lower electricity quantity during periods of high power demand within a community or community where a home or house 32 is located.

In the present application, the term module, including the definitions below, may be replaced by the term circuit. The terminology module may be an application specific integrated circuit (ASIC); Digital, analog, or hybrid analog / digital separation circuitry; Digital, analog or mixed analog / digital integrated circuits; Combinatorial logic; A field programmable gate array (FPGA); Processor (shared, private, or group) executing the code; Memory (shared, private, or group) that stores code executed by the processor; Other suitable hardware components that provide the aforementioned functions; Or a combination of some or all of the above elements, such as a system-on-chip.

The foregoing description is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. The various teachings of the specification may be implemented in various forms. Thus, while this description includes specific embodiments, its true scope should not be limited thereby, as other modifications will become apparent on the basis of study of the drawings, specification and the following claims. At least one of the phrases A, B, and C used herein should be interpreted to mean logic (A or B or C) using a non-exclusive logic 'or. It should be understood that one or more procedures within a method may be performed in a different order (or concurrently) without altering the principles of the invention.

The description of the preceding embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to this. The individual elements or features of a particular embodiment are not generally limited to that specific embodiment and, if applicable, may be replaced and used in the selected embodiment, even if not specifically shown or described. The same element can be changed in various ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the present invention.

Claims (26)

In a climate control system,
A variable capacity compressor unit operable in a first capacity mode and a second capacity mode higher than the first capacity mode; And
And a control module configured to control the variable displacement compressor unit,
The control module is configured to switch the variable capacity compressor unit from the operation stop state to the first capacity mode in response to receiving the request signal,
The control module
A comparison of the outdoor air temperature with a predetermined temperature value, and
Wherein the previous second capacity operation time is shorter than the second capacity operation time of the second capacity operation time threshold from the previous initial of the second capacity mode until the previous request is met, Based on the comparison being the amount of previous time while operating in the mode,
And to selectively switch the compressor unit from the first capacity mode to the second capacity mode. 2. The climate control system of claim 1, wherein the control module switches the compressor unit from the first capacity mode to the second capacity mode while receiving the same request signal. 2. The system of claim 1, further comprising a comfort control interface configured to be located at one of a plurality of comfort level set values, wherein a first one of the comfort level set values corresponds to an energy efficiency operating mode, And the second set value of the comfort level setting values corresponds to the high performance operation mode. 4. The climate control system of claim 3, wherein the control module is configured to compare the compressor operating time to a first capacity operating time threshold. 2. The climate control system of claim 1, further comprising a thermostat once configured to generate the request signal. A method for controlling a compressor unit operable in a low capacity mode and a high capacity mode, the method comprising:
Receiving a request signal from the thermostat;
Setting a low-capacity operation time threshold value based on the selected comfort level;
Operating the compressor unit in a low capacity mode in response to receipt of the request signal;
Comparing the operation time of the compressor unit with the low-capacity operation time threshold value; And
And switching the compressor unit from the low capacity mode to the high capacity mode based on a comparison of the operation time and the low capacity operation time threshold value. 7. The method of claim 6, further comprising setting a high capacity operation time threshold value based on the selected comfort level. 8. The method of claim 7, further comprising switching the compressor unit from the high capacity mode to the low capacity mode based on a comparison of the operating time and the high capacity operation time threshold. The method of claim 6, further comprising setting a set point temperature at which the request signal is to be transmitted. 7. The method according to claim 6, wherein the comfort level is set based on a geographical area in which the compressor unit is installed and a climate type in which the compressor unit is installed. 7. The method of claim 6, wherein the selected comfort level is set using a comfort control interface configured to be set to one of a plurality of comfort level setting values, wherein a first set value of the comfort level setting values is energy efficiency Wherein the second set value of the comfort level set values corresponds to a high performance mode of operation. 12. The method of claim 11, wherein the comfort control interface comprises at least another comfort level setting value between a first set value and a second set value of the comfort level set values. 12. The method of claim 11, wherein the comfort control interface is configured to be manually positioned in one of the plurality of comfort level settings. 12. The air conditioner according to claim 11, wherein the low-capacity operation time threshold value is smaller than when the comfort control interface is set to the second set value of the comfort level setting values, 1 < / RTI > set value. 7. The compressor of claim 6, wherein the compressor unit is switched from the shutdown state to the low capacity mode in response to receipt of the request signal and the compressor unit is switched from the low capacity mode to the high capacity mode while receiving the same request signal ≪ / RTI > 7. The method of claim 6, wherein the thermostat is a thermostat. In a climate control system,
A compressor unit operable in a low-capacity mode and a high-capacity mode; And
And a control module configured to control the compressor unit,
Wherein the control module is configured to switch the compressor unit from a shutdown condition to the low capacity mode in response to receipt of a request signal,
The control module
Setting a low-capacity operation time threshold value based on a user-selected comfort level;
Compare the operating time of the compressor unit with the low capacity operating time threshold;
Change the compressor unit from the low capacity mode to the high capacity mode based on a comparison of the operation time and the low capacity operation time threshold value; And a climate control system. 18. The climate control system according to claim 17, wherein the control module sets a high-capacity operation time threshold value based on the user-selected comfort level. The climate control system according to claim 18, wherein the control module switches the compressor unit from the high-capacity mode to the low-capacity mode based on a comparison between the operation time and the high-capacity operation time threshold value. 18. The climate control system according to claim 17, wherein the comfort level is set based on a geographical area in which the compressor unit is installed and a climate type in which the compressor unit is installed. 18. The method of claim 17, further comprising: a comfort control interface configured to set the user-selected comfort level to one of a plurality of comfort level set values, wherein the first set value of the comfort level set values is energy efficiency And the second set value of the comfort level setting values corresponds to the high performance operation mode. 22. The climate control system according to claim 21, wherein the comfort control interface includes at least another comfort level setting value between a first setting value and a second setting value of the comfort level setting values. 22. The climate control system of claim 21, wherein the comfort control interface is configured to be manually positioned in one of the plurality of comfort level settings. 22. The method of claim 21, wherein the low-capacity operation time threshold value is less than when the comfort control interface is set to a second set value of the comfort level setting values, Lt; RTI ID = 0.0 > 1, < / RTI > 18. The system of claim 17, wherein the compressor unit is switched from the operation stop condition to the low capacity mode in response to receipt of the request signal, and the compressor unit is switched from the low capacity mode to the high capacity mode while receiving the same request signal Wherein the climate control system comprises: 26. The climate control system of claim 25, further comprising a once thermostat configured to generate the request signal.

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