CN101713397A - 压缩机保护和诊断系统 - Google Patents
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Abstract
本发明涉及压缩机保护和诊断系统,特别是一种压缩机和一种方法。压缩机包括:至少一个电流传感器;和处理电路,处理电路与至少一个电流传感器通信并且能够操作以当压缩机引出的电流为峰值锁定转子电流的至少百分之四十时给出锁定转子情况。所述方法包括:启动压缩机的电机;记录电机引出的电流持续所述启动后的第一预定时长;将电机在第一预定时长期间引出的最高电流与电机在第一预定时长后引出的运行电流进行比较;以及当运行电流超过最高电流至少百分之四十时给出锁定转子情况。
Description
本申请是申请日为2004年12月30日、申请号为200480015875.3、发明名称为“压缩机保护和诊断系统”的中国发明专利申请的分案申请。
相关申请的交叉引用
本申请要求2003年12月30提交的U.S.临时申请号No.60/533,236的权益。上述申请的内容在这里结合作为参考。
技术领域
本技术涉及压缩机,尤其涉及一种用于压缩机的改善的诊断系统。
背景技术
压缩机广泛用于工业和住宅应用中。尤其地,压缩机经常用于制冷装置的循环制冷或用于提供理想加热或冷却效果的热泵系统。此外,压缩机还用于膨胀或给外部物体,如轮胎、洒水系统或气动工具以流体力。在前述的任何应用中,希望压缩机提供一致和有效的操作,从而确保特定的应用(即,制冷系统或气动工具)正常工作。最后,当压缩机终止运转或需要修复时发出帮助信号,从而防止压缩机不必要的损坏和系统故障。
为了压缩机的寿命,要使压缩机不出故障地运转并提供一致的压缩流体供给。尽管压缩机越来越可靠,但使压缩机中断其操作的压缩机检测操作出现了误差或故障。在不利的条件下中断涡旋式压缩机的使用可能阻止给压缩机带来损坏。
导致压缩机关闭的故障实际上是电力的或机械的。电力故障一般在压缩机中的电机上具有直接效果,并损坏电机或与其相关的组件。机械故障包括错误的负荷或断裂部分,其一般将各个组件的内部温度提高非常高的级别,有时会给压缩机带来故障和损坏。除了机械的和电力的故障之外,也可发生“系统”故障,例如由制冷剂或润滑剂的不利级别导致的故障,或导致阻塞流动条件的故障。这种系统故障将内部压缩机温度或压力提高到可损坏压缩机的很高级别。
发明内容
压缩机组件一般包括壳,装在所述壳内的压缩机,与所述压缩机驱动相连的电机。设置传感器组件,用于监控所述压缩机的操作参数。该参数包括给电机供给电流的电导体的温度。与传感器组件通信的处理电路处理压缩机的操作参数。终端组件密封地固定到所述壳并与传感器组件通信,而一个连接器连接到壳外部的终端组件,并用于将处理电路与传感器组件相连。
一种压缩机,包括:至少一个电流传感器;和处理电路,所述处理电路与所述至少一个电流传感器通信并且能够操作以当所述压缩机引出的电流为峰值锁定转子电流的至少百分之四十时给出锁定转子情况。
一种方法,包括:启动压缩机的电机;记录所述电机引出的电流持续所述启动后的第一预定时长;将所述电机在所述第一预定时长期间引出的最高电流与所述电机在所述第一预定时长后引出的运行电流进行比较;以及当所述运行电流超过所述最高电流至少百分之四十时给出锁定转子情况。
附图说明
通过详细的描述和附图,将更加完全地理解本发明,其中:
图1是结合有依照本发明第一个保护系统的压缩机的透视图;
图2是图1压缩机的横截面图;
图3是图2所述保护系统的更详细的截面图;
图4是图2所述保护系统的透视图;
图5是图2所述保护系统的示意性表示;
图6是图2所述保护系统的可选择的示意性表示;
图7是结合有依照本发明第二个保护系统的压缩机的透视图;
图8是图7压缩机的横截面图;
图9是图7所述保护系统的更详细的截面图;
图10是图7所述保护系统的透视图;
图11是图7所述保护系统的示意性表示;
图12是结合有依照本发明第三个保护系统的压缩机的透视图;
图13是图12保护系统的束块(cluster block)的透视图;
图14是结合进电流传感器组件中的图13的束块的透视图;
图15是结合进外壳中的图14的束块和电流传感器组件的前视图;
图16是结合进外壳并装配到图12所述压缩机的图14的束块和电流传感器组件的前视图;
图17是描述依照本发明的压缩机操作的流程图;
图18是依照本发明描述在运转状态和关闭状态之间的压缩机操作的流程图;
图19是结合有依照本发明第四个保护系统的压缩机的透视图;
图20是图19压缩机的横截面图;
图21是图19保护系统的透视图;
图22是显示电流传感排列的图20保护系统的透视图;和
图23是依照本发明的压缩机网络的示意性表示。
具体实施方式
下面的描述实际上仅仅是示意性的,并不意在限制本发明、其应用或使用。
参照附图,提供了涡旋式压缩机10,其包括压缩机保护和控制系统12。保护和控制系统12响应于传感到的压缩机参数而选择地关闭压缩机10,从而保护压缩机10并在当条件不利时阻止其操作。尽管这里描述了涡旋式压缩机10,但应当理解到,任何压缩机都可使用本发明的保护和控制系统12。
特别参照图1和2,压缩机10显示为包括一般的柱形封闭外壳14,所述外壳具有焊接在顶部的帽16和具有焊接在底部的多个脚20的基部18。所述帽16和基部18固定到外壳14,从而确定出压缩机10的内部体积。帽16设置有排放装置24,同时外壳14类似地设置有进口装置26,一般设置在帽16和基部18之间,如图2和8中所示。此外,电力罩28固定地连接到一般在帽16和基部18之间的外壳14,并可操作地支撑其中的一部分保护系统12,如下面进一步讨论的。
机轴30相对于外壳14由电机32旋转驱动。电机32包括由封闭外壳14固定支撑的定子34、经过那里的线圈36和压迫固定在机轴30上的转子38。操作电机32和相关的定子34、线圈36和转子38相对于外壳14驱动机轴30,由此压缩流体。
压缩机10还包括驱动涡旋元件40,该元件在其上表面上具有螺旋叶片或缠绕(wrap)42,用于接收并压缩流体。在驱动涡旋元件40和支撑外壳46之间固定有欧式联轴节44,其用于键入驱动涡旋元件40和非驱动涡旋元件48。欧式联轴节44用于将机轴30的旋转力传给驱动涡旋元件40,从而压缩位于驱动涡旋元件40和非驱动涡旋元件48之间的流体。欧式联轴节44及其与驱动涡旋元件40和非驱动涡旋元件48的交互作用优选为受让人共同拥有的U.S.专利No.5,320,506中公开的类型,其内容在这里结合作为参考。
非驱动涡旋元件48也包括设置成与驱动涡旋元件40的缠绕42啮合结合的缠绕50。非驱动涡旋元件48具有设置在中心的排放通路52,其与向上的开放凹口54相通。凹口54与由帽16和隔离物56确定的排放装置24流体连通,从而被压缩的流体通过通路52、凹口54和装置24离开外壳14。非驱动涡旋元件48设计成以合适的方式装配到支撑外壳46,所述合适的方式如前述的U.S.专利No.4,877,382或U.S.专利No.5,102,316中公开的方式,其内容在这里结合组为参考。
现在参照图2,电力罩28包括下部外壳58、上部外壳60和腔62。下部外壳58使用多个螺管脚64装配到外壳14上,所述螺管脚焊接或以其他方式固定连接到外壳14。上部外壳60匹配地被下部外壳58接收,并在其间确定腔62。腔62用于容纳压缩机保护和控制系统12地各个组件,将在下面进一步讨论。
特别参照图1-6,压缩机保护和控制系统12显示为包括传感器系统66、处理电路68和电力中断系统70。传感器系统66、处理电路68和电力中断系统70共同协作来探测和纠正故障状况,以尽力防止损害压缩机10并提醒使用者故障状况(即,通过发光器件(LED)等)。压缩机保护和控制系统12探测并响应于运转线圈延迟、电机过载、错相、反相、电机线圈电流不平衡、断路、低压、锁定转子电流、过高的电机线圈温度、较高的排放温度情况、较低的油压、缺少三相电、断开的热敏电阻器、焊接的或断开的接触器和短循环(short cycling)。例如,表1种简要描述了特定类型和尺寸压缩机的压缩机保护和控制系统12,但其它压缩机种类和尺寸可具有不同的阈值、参数、指示器和极限。
表1
报警 | 出现的情况 | 动作 | LED | 锁定 | 重设 |
运转线圈延迟 | 在激活第一个线圈之后的一个线圈激活中过多的延迟 | 跳闸(断开接触式继电器),等待5分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁一次 | 在一行中10次跳闸 | 正常运转线圈操作或循环电力 |
错相 | 错过一个相位 | 跳闸(断开接触式继电器),等待5分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁两次 | 在一行中10次跳闸 | 存在全部三个相位或循环电力 |
报警 | 出现的情况 | 动作 | LED | 锁定 | 重设 |
反相 | 错误连接三相电线,导致电机反相运转 | 跳闸(断开接触式继电器),等待5分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁三次 | 在一行中4次跳闸 | 相位方位修正或循环电力 |
焊接的接触器 | 当接触器应该断开时,接触器给压缩机提供三相电 | 没有 | 在脉冲之间红灯闪烁四次 | 没有 | N/A |
低电压 | 供给AMPS的电压低于报警阈值 | 跳闸(断开接触式继电器),等待5分钟 | 在脉冲之间红灯闪烁五次 | 没有 | 供给电压保持在“正常”范围内 |
没有三相电 | 当存在需求时在压缩机端口处没有探测到电流 | 没有 | 在脉冲之间红灯闪烁五次 | 没有 | 当存在需求或不存在需求时探测三相电流,且没有探测到电流 |
低油压 | 在延长的一个时间周期,油压过低 | 跳闸(断开接触式继电器),当油继电器关闭时关闭接触式继电器 | 在脉冲之间红灯闪烁一次 | 没有 | 油压传感器警报继电器打开 |
排放温度 | 排放温度过高 | 跳闸(断开接触式继电器),等待30分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁两次 | 3个小时4次跳闸 | 排放温度保持在“正常”范围或循环电力 |
电机温度 | 电机温度过高或电机温度传感器短路 | 跳闸(断开接触式继电器),等待30分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁三次 | 3个小时4次跳闸 | 电机温度保持在“正常”范围或循环电力 |
锁定转子 | 压缩机的电流超过300Amp或不能降低原始锁定转子电流级别,或超过300Amp或为运转时峰值锁定转子Amp(LRA)的40% | 跳闸(断开接触式继电器),等待5分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁四次 | 一行中4次跳闸 | 压缩机的电流保持在“正常”范围或循环电力 |
电机过载 | 压缩机的电流超过最大连续电流(MCC)等级 | 跳闸(断开接触式继电器),等待5分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁五次 | 没有 | 压缩机电流保持在“正常”范围内 |
断开的热敏电阻器 | 一个或多个排放/电机温度传感器为断开 | 跳闸(断开接触式继电器),等待30分钟,然后关闭接触式继电器 | 在脉冲之间红灯闪烁六次 | 没有 | 排放温度保持在“正常”范围或循环电力 |
由上面表1可以看出,运转线圈延迟一般定义为在给第一线圈供电后的一个线圈供电中的过多延迟。当启动线圈已经被供电后,运转线圈必须在两秒钟内被供电。如果运转线圈在该时间周期中没有被供电,则系统12就关闭压缩机电机32。如果运转线圈第一次被供电,则在两秒钟之内必须给启动线圈供电。如果启动线圈没有在该时间周期内被供电,则系统12同样关闭电机32。对于多个压缩机10c(图19),系统12在开动时感应开始和运转线圈电流。当压缩机10c在运转状态中时,如果启动线圈或运转线圈完全不运转超过两秒钟,则系统12就关闭电机32。
当电机32的一个相位错过时通常定义为错相故障。一旦启动线圈被充电,则系统12就确保在一个相位中探测到电流后,在700毫秒内的所有相位中都存在电流。如果在至少一个相位中探测到电流,在其它相位中没有探测到电流,则系统12就关闭电机32。一般来说,在电机32被打断之前,要求超过百分之50的电流不均衡。监控运转线圈,并以类似的方式避免其错相。在正常的运转操作(即存在要求时)过程中,如果在电机32任何相位中的电流损耗探测为一秒的周期,则就关闭电机32。
当不正确连接三相电线时一般定义为反相,由此使得电机32向回运转。如果三相电的相位序列不正确,则系统12就关闭压缩机10。在启动线圈中感应到命令信号和电流之后,大致测量相位序列700毫秒。应当注意到,在电力已经从压缩机10移除之后,由于压力均等原理,所以电机32“向回”旋转一个较短的时间周期。由于该现象,所以仅仅在每个压缩机开始循环周期的第一个五秒监控反相。
当接触器应当是断开的时候接触器给压缩机供给三相电时出现了焊接的接触器故障。在已经关闭电机32之后探测到该情况。如果在关闭之后大约两秒后电流仍持续,则就假定触点已经被焊接或机械地“塞上”。
电机过载情况一般称作下面这种情况,即压缩机10的电流超过了最大连续电流(MCC)等级的情况。过载电流定义为超过百分之110额定MCC达60秒钟以上的电流。如果在开始或运转线圈的任何一个引线中的部分线圈电机电流超过了预定设计的极限,则系统12就关闭电机32。MCC过载探测直到在启动后五秒才开始,并一直持续到关闭。如果没有设计压缩机的MCC,则通过电机温度传感器探测过载电流。当确定对于压缩机10错误地将MCC值设为零Amp时,系统12探测缺少的压缩机MCC参数。
当压缩机10的电流超过大约300Amp、不能降低原始的锁定转子电流级别、超过300Amp、或为运转时峰值锁定转子Amp(LRA)的大约40%时出现了锁定转子情况。希望在电机32达到速度并稳定于正常运行电流级别之后一秒内降低在启动过程中锁定转子的电流。系统保持了用于运转和启动线圈的100毫秒电流的缓冲。当压缩机需求较高时,表示压缩机已经启动,在缓冲中的最高峰值电流记录为锁定转子电流。峰值锁定转子电流记录为超过300Amp,或如果小于30Amp则记录为特定的峰值。
如果启动线圈中的峰值锁定转子电流大于300Amp,则在启动之后(测量出压缩机需求较高)大约800毫秒采取第二读取。如果在启动之后800毫秒,启动线圈电流值大于300Amp,则系统12就假定可机械卡住电机32,且应当切断电机32的电力。如果在启动线圈中的峰值锁定转子电流小于300Amp,则在启动之后(测量出压缩机需求较高)大约800毫秒采取第二读取。如果第二读取不能降低到小于所测量的峰值LRA的40%的一个等级,则就切断压缩机电机32的电力。
对于在完成启动之后发生的锁定转子情况,使用测量的峰值锁定转子电流。如果峰值锁定转子电流大于300Amp,且运转电流测量为在300Amp以上500毫秒,则就切断电机32的电力。如果峰值锁定转子电流小于300Amp,且运转电流大于所测量和记录的峰值锁定转子电流的40%,则类似地切断电力。如果测量到小于100Amp的峰值锁定转子电流,则锁定转子探测对于压缩机运转循环是无能力的。如果在设备的故障检测过程中中断启动的定时,则这种控制就消除了有害的跳闸。
当存在压缩机命令信号时如果给系统12施加的220VAC供给电力下降到170VAC以下,则就出现了低电压故障,且压缩机12关闭。当电压下降到该级别时,就不允许压缩机10启动。在低电压情况中由于接触器线圈振动而造成的过多的放电会导致焊接的接触器,由此在这种条件下关闭压缩机10。在警报记录且切断电机32的电力之前,低电压的发生必须持续大约两秒钟。电压必须上升到180VAC以上最少两秒钟,以重设警报。
监控排放温度,以确保排放温度不高于预定的门槛值,以尽力保护电机32和相关的涡旋元件40,48。系统12在至少两个位置处监测排放温度,且如果电阻值大于大约1.33k+/-百分之5,则切断电机32的电力。保持切断电力一直到电阻降到大约600+/-百分之5以下且已经完成了三十(30)分钟延迟。
通过使用至少一个正温度系数(PTC)器件或负温度系数(NTC)器件,可以为热敏电阻型传感器,来监测电机32的温度。如果PTC电阻值大于大约4.5k+/-百分之5,就切断电机32的电力并保持这种状态一直到PTC电阻降到大约2.75k+/-百分之5以下且已经完成了三十(30)分钟延迟。短路的热敏电阻输入读做低电阻值,并表示各个电机温度传感器已经跳线(jumpered)或板组件已经出现故障。任何低于大约100欧姆的PTC电阻都认为是短路热敏电阻器。
如果任何热敏电阻器输入都读作开放电路,则就出现了开放热敏电阻器故障,且切断电机32的电力。对NTC和PTC热敏电阻器开放电路定义为电阻高于大约100k。当压缩机10运行时,电阻必须在该等级读取60秒钟。
如果压缩机命令输入被读取为高且达两秒钟,则在任何电流转换器输入中都没有读到电流,没有出现三相电警报。无论何时在任何电流转换器输入中探测到电流或如果命令输入读取为低且达两秒钟,则都重设警报。
除了探测和报告上述故障情况(表1)之外,系统12还探测和监控“警告情况”。警告情况不用作故障情况,因此不会产生保护动作(即切断电机32的电力),但虽然如此,警告情况被监控并用作诊断,以阻止故障情况。警告情况包括较高的周围温度警告、电机过载警告、锁定转子警告、低供给电压警告、高电压警告、高排放温度警告、排放温度传感器短路警告、高电机温度警告、无配置警告以及接触器寿命警告,在下面简要描述其每一个。
当周围温度传感器连续测量超过大约60摄氏度的温度超过60秒时,就出现较高的周围温度警告。当周围温度传感器连续测量低于60摄氏度的温度超过60秒时重设所述较高的周围温度警告。
当电机电流处于百分之100MCC电流级别超过60秒钟时发出电机过载警告。当电机电流级别降低到百分之100MCC电流级别以下超过60秒钟时或当电机过载警报起作用时重设电机过载警告。
当探测到锁定转子事件时发出锁定转子警告。不像要求多个事件的警报,该警告以单个事件来探测。当压缩机10在不具有锁定转子事件的情况下连续运转五分钟时,或当锁定转子警报起作用时重设该锁定转子警告。
当施加电压低于180VAC两秒钟时发出低施加电压警告。当施加电压高于190VAC两秒钟时或当低施加电压警告起作用时重设低电压警告。
当施加电压高于250VAC两秒钟时发出高施加电压警告。当施加电压高于240VAC两秒钟时重设高施加电压警告。
当排放温度小于每个传感器警告设定点以下10摄氏度两秒钟时发出高排放温度警告。当排放温度大于每个传感器警告设定点以下15摄氏度两秒钟,或高排放温度警告起作用时重设高排放温度警告。
当在排放温度传感器处测量的电阻小于100两秒钟时发出排放温度传感器短路警告。当测量的电阻大于1k两秒钟时重设排放温度传感器短路警告。
当电机温度小于警告设定点以下10摄氏度两秒钟时发出高电机温度警告。
当电机温度大于警告设定点以下15摄氏度两秒钟时,或高电机温度警告起作用时重设高电机温度警告。
当压缩机模块数、序列号和MCC电流没有编进存储器中时发出无配置警告。当压缩机模块数、序列号和MCC电流编进存储器时重设无配置警告。这里对模块和序列号在文本中的精确性没有进行检测,且MCC值的任何非零数都是有效的。
当压缩机启动次数等于50,000或50,000的倍数(即100k,150k,200k等)时发出接触器寿命警告。当系统模块电力关闭和打开时,即表示接触器已经被检查和/或替换时,重设接触器寿命警告。
一般地,传感器系统66探测压缩机操作情况,如在表1中列出的压缩机故障和压缩机警告情况,并给那里表示的处理电路68发出信号。处理电路68是微控制器或微处理器,如由Arizona,Chandler的微芯片技术制造的微控制器模块号PIC18F242。处理电路68与电力中断系统70通信,并响应于由传感器系统66探测到的不利情况,如,但并不限于此,前述的“故障情况”而选择性地开动电力中断系统70。电力中断系统70响应于处理电路68的指令而选择性地限制压缩机电机32的电力,从而当所传感到的压缩机操作情况在预定极限之外时阻止对压缩机10的损害。
特别参照图3-6,传感器系统66包括涡旋传感器72、电机温度传感器74、和转子传感器76。涡旋传感器72一般靠近驱动涡旋元件40和非驱动涡旋元件48设置,从而可以探测驱动涡旋元件50和非驱动涡旋元件48周围区域中的温度。电机温度传感器74一般靠近电机32的线圈36设置,并探测线圈36周围的温度。
转子传感器76接近电机32的转子38设置,并当转子38在“锁定转子情况”时进行感应。当限制转子38相对于线圈36移动时,在线圈36和转子38之间就会施加一个力,因为机轴30设法使线圈36旋转。可以理解到,当电机32试图旋转机轴30,并由于相对于线圈36的转子38的锁定情况而限制电机32这么做时,过量的电流就从外部电源引出,且转子38经历了升高的温度。转子传感器76监控所述引出电流的增加,以致如果探测到预定电流就关闭压缩机10,将在下面进一步讨论。
特别参照图4,传感器系统66显示为进一步包括束块(cluster block)78和印刷电路板(PCB)80。束块78包括外壳82、电力开口84和传感器开口86。电力开口84与从外壳82延伸的三个高压线88连接。高压线88给电机32供应电力,由此驱动机轴30和驱动涡旋元件40。高压线88从外壳82延伸并在PCB80处终止,如图4中所示。
PCB80可支撑与电机32紧密靠近的电机温度传感器74和转子传感器76。电机温度传感器74设置在PCB80的底表面上并与电机32的线圈36紧密靠近,从而电机温度传感器74能探测线圈36中的温度变化。电机温度传感器74是能探测线圈36中温度波动的热敏电阻器,其根据特定的用途可以配置为NTC或PTC器件。如果电机温度传感器74配置为NTC器件,则来自电机温度传感器74的信号并联。如果电机温度传感器74配置为PTC器件,则来自电机温度传感器74的信号为串连。
转子传感器76一般设置在PCB80与电机温度传感器74相对的一侧,如图4中所示。转子传感器76一般包括与每个高压线88的终端电力连接的传感器管脚90。传感器管脚90特别设计成电流承载元件,使每个管脚的内部电阻仅局限于沿其几何方向的特定点处,所述几何方向表示通过每个管脚90流动的电流方向。可以理解到,通过每个传感器管脚90流动的电流由电机32引出的电流量来表示。当转子38在锁定状态中时,电机32开始通过每个管脚90引出更多电流,由此增加在局部点处每个管脚90的温度,其将在下面进一步讨论。
除传感器管脚90外,转子传感器76进一步包括温度传感器92,其靠近每个传感器管脚90设置,如图4中所示。温度传感器92探测沿传感器管脚90长度的温度的变化,其可以配置为NTC或PTC热敏电阻器。一般来说,每个温度传感器92都沿每个传感器管脚90的长度设置,从而其靠近电阻增加的所述局部点,以最好地探测沿每个单个管脚90长度的温度变化。可以理解到,当电机32通过每个传感器管脚90引出更多电流时,每个管脚90将在所述局部点处经历电阻,如前面所讨论的。通过将每个温度传感器92设置在沿每个传感器管脚90靠近所述电阻局部点处,将会快速和准确地探测由通过每个传感器管脚90引出的增加的电流所导致的温度波动,并能反馈给处理电路68,其在下面将进一步讨论。
除支撑电机温度传感器74和转子传感器76之外,PCB80还与涡旋(scroll)传感器72连接,如图4中所示。涡旋传感器72是温度传感器,并可探测靠近于驱动涡旋元件40和非驱动涡旋元件48的、或由驱动涡旋元件40和非驱动涡旋元件48所引起的温度波动。涡旋传感器72是热敏电阻器,根据特定的用途,其可配置为NTC热敏电阻器或PTC热敏电阻器。
PCB80用作涡旋传感器72、电机温度传感器74、传感器管脚90和温度传感器92的终点。具体地说,涡旋传感器72通过低压线94与PCB80连接,同时电机温度传感器74和温度传感器92直接连接到PCB80并由PCB80支撑,如图4中所示。如前面所讨论的,每个涡旋传感器72、电机温度传感器74和转子传感器76可探测在压缩机10的壳14内部的各个温度波动。由于涡旋传感器72、电机温度传感器74和转子传感器76中的每一个都终止在PCB80处,所以PCB80可用作一个继电器,以将来自各个传感器72,74,76每一个的所感应的信号通过压缩机10的壳14传送给处理电路68和电力中断系统70。
低压线96从PCB80延伸到束块78,并与传感器开口86连接。可以理解到,从PCB80延伸到束块78的低压线96的数量依赖于设置在压缩机10的内部体积22中的传感器的数量。换句话说,从PCB80延伸到束块78的低压线的数量一般等于设置在压缩机10内部的传感器72,74,92的数量。然而,来自各个传感器72,74,92的每个信号被合并从PCB80发送到束块78,从而传送到处理电路68和70,由此在PCB80和束块78之间需要单根延伸的导线。可以理解到,通过合并来自各个传感器72,74,92的信号,可减小从PCB80延伸到束块78的线96的数量。
如前面所讨论的,传感器组件66与处理电路68通信。为了保持压缩机10的内部体积22的真空密封,设置密封终端组件98,以在传感器组件66和处理电路68之间建立电连接,如图3中所示。
密封终端组件98包括外壳100、多个高压管脚102、多个低压管脚104和围绕高压低压管脚102,104的真空密封材料106。外壳100通过适宜的方式,如焊接或焖,而固定连接到压缩机10的壳14。高压和低压管脚102,104通过外壳100延伸,以致高压和低压管脚102,104从内部体积22延伸到压缩机10的外部表面,如图3中所示。高压和低压管脚102,104被真空密封材料106包围,以致由每个管脚102,104和外壳100的外部表面形成真空密封。这样,在保持压缩机10的真空密封的同时,终端组件98在传感器组件66和处理电路68之间进行有效通信。
处理电路68设置在压缩机10的外表面,并与终端组件98和传感器组件66通信。具体地说,处理电路68一般容装在电外壳28内,并结合进适宜的插头108中,以与密封终端组件98相互作用。依靠组件,插头108接收每个高压和低压管脚102,104,以致在处理电路68和密封终端组件98形成电力连接。此外,将高压和低压管脚102,104分别接收进束块78的电力开口84和传感器开口86中。这样,在处理电路68和传感器组件66之间通过密封终端组件98和插头108进行电力连接。尽管已经描述了插头108,应当理解到,任何适宜的连接器都可用于将压缩机10内的信号传送给处理电路68。
除了与密封终端组件98和传感器组件66电力连接之外,处理电路68还与电力中断系统70连接。电力中断系统70设置在压缩机10的外表面上并选择性地允许给电机32供电和限制给电机32供电。可以理解到,当传感器72,74,92指示传感器10内情况不利时,处理电路68将指导电力中断系统70限制电力到达电机32,由此有效关闭压缩机10。这样,当压缩机10内,或结合有压缩机10的系统内部的条件不利于进一步操作时,传感器组件66、处理电路68和电力中断系统70就可通过限制给电机32供电而关闭压缩机10。
除上面讨论的以外,处理电路68还存储压缩机10的配置参数。具体地说,压缩机模块、压缩机序列号(serial number)、电机传感器类型、MCC等级(level)、排放温度、电机温度、电流转换器校准偏移量、自控(slave)寻址和器件名都存储在处理电路68中。上面的参数,仅仅压缩机模块、序列号、自控寻址和器件名为字段(field)配置。
特别参照图5和6,将详细描述压缩机10和相关压缩机保护及控制系统12的操作。如前面所讨论的,电力中断系统70控制导向压缩机10的电机32的电力,通过选择性地接合设置在压缩机10外部的接合部110从而选择性地抑制和允许给电机32供电而导向电机32。
操作时,处理器68监控电机温度传感器74和涡旋温度传感器72的合并信号,并响应于探测到的系统参数选择性地关闭压缩机10。具体地说,如果由电机温度传感器74或涡旋温度传感器72探测到的温度的实际值超过了预定极限,从而探测到了故障条件,则处理电路68就指导电力中断系统70断开接合部110,由此抑制电力到达电机32。此外,处理电路68还产生故障信号,并将该信号传导到诊断输出112,以便记录。可以理解到,压缩机10内登记的故障是在追踪并阻止进一步的故障和压缩机10内的失灵方面有价值的诊断工具,通过将故障信号传送到诊断输出112,每次压缩机10关闭时处理电路68都有效登记,并保持所经历的每个故障情况的记录。
如前面所讨论的,当转子38相对于线圈36被锁定时转子传感器76开始探测。当转子38在“锁定转子情况”中时,电机32仍通过传感器管脚90引出电流,试图相对于线圈36旋转机轴30和转子38。在这样做时,电机32通过每个传感器管脚90引出大量电流,以克服转子38和线圈36之间的锁定情况,由此增加了每个传感器管脚90的温度。当传感器管脚90实现了温度增加时,温度传感器92就将表示温度增加的信号传递回处理电路68。
当温度传感器92指示在每个管脚90处的温度增加时,处理电路68使感应到的温度与流过每个管脚90的电流相关。这样,温度传感器92与处理电路68合作,以有效用作监控流过每个管脚90的电流并探测锁定转子情况的电流传感器。当通过管脚90建立阈值电流时,处理电路68就指导电力中断系统70来限制给电机32供电并关闭压缩机10。
除了给电力中断系统70发送信号以外,处理电路68还给诊断输出112发送诊断信号,以记录在压缩机10内经历的“锁定转子”故障。通过存储和跟踪故障,压缩机保护和控制系统12可有效使使用者监控并跟踪压缩机10所经历的问题,以尽力阻止并探测将来的问题,如前面所讨论的。
压缩机保护和控制系统12已经描述为具有三个温度传感器92,每个都靠近传感器管脚90设置。图5示意性地表示了从每一个温度传感器92到处理电路68的输入。然而应当理解,三个温度传感器92被供给到一个信号中,由此通过密封终端组件98将该单个信号发送到处理电路68,如图6中所示。在这种关系中,通过减少来自单个温度传感器92的信号数而简化了系统12。除了前述的传感器72,74,76之外,应当理解到,在压缩机10内可使用其他传感器,且应当认为是本发明的一部分。具体地说,可以预见到,还可以将油面(oil level)传感器或油温传感器(图6中一般称作114)结合进压缩机保护和控制系统12,用于压缩机内的跟踪诊断,应当理解在本发明的范围内。
特别参照图7-11,将详细描述压缩机保护和控制系统12的第二个实施方案。考虑到与压缩机保护和控制系统12和压缩机保护和控制系统12a相关的组件在结构上和功能上的大致相似性,在这里和附图中使用相同的参考数字来表示相同的组件。
对于涡旋传感器72和电机温度传感器74,压缩机保护和控制系统12a以与压缩机保护和控制系统12相似的方式运作。这样,在先已经详细描述了涡旋传感器72和电机温度传感器74。
在电箱28内设置有转子传感器76a,其一般包括与高压线88电连接的传感器管脚90。传感器管脚90具体设计为电流承载元件,并将每个管脚的内部电阻局限在沿其几何方向的特定点处,所述几何方向表示通过每个管脚90流动的电流。可以理解到,通过每个传感器管脚90流动的电流由电机32引出的电量来表示。当转子38在锁定状态时,电机32开始通过每个管脚90引出更多电流,由此增加了在所述局限点处的每个管脚90的温度,将在下面进一步描述。
除传感器管脚90以外,转子传感器76进一步包括温度传感器92,其靠近每个传感器管脚90设置。温度传感器92探测沿传感器管脚90长度的温度的变化,其可以配置为NTC或PTC热敏电阻器。一般来说,每个温度传感器92都沿每个传感器管脚90的长度设置,从而其靠近电阻增加的所述局部点,以最好地探测沿每个单个管脚90长度的温度变化。可以理解到,当电机32通过每个传感器管脚90引出更多电流时,每个管脚90将在所述局部点处经历电阻。通过将每个温度传感器92设置在沿每个传感器管脚90靠近所述电阻局部点处,将会快速和准确地探测由通过每个传感器管脚90引出的增加的电流所导致的温度波动,并能反馈给处理电路68。
转子传感器76a允许处理电路68更快速地响应由电机32引出的电流增加,并因此增加了压缩机保护和控制系统12a的能力,从而保护压缩机10。更特别地,因为转子传感器76a设置在压缩机内部空间22的外部,所以由电机32引出的电力在实际进入压缩机壳14之前可以被监控。监控从电机32上游引出的电流可允许较快的响应时间,因为在读取之前,处理电路68不需要等待沿高压线88并通过密封界面98流动的电流。提高的响应时间使处理电路68更快速地指导电力中断系统70,从而限制给电机32供电,因而减小了压缩机损坏的可能性。
特别参照图12-18,将更详细地描述压缩机保护和控制系统12的第三个实施方案。考虑到与压缩机保护和控制系统12以及压缩机保护和控制系统12a相关组件在结构上和功能上的大致相似性,在这里和附图中使用相同的参考数字来表示相同的组件。
对于涡旋传感器72和电机温度传感器74,压缩机保护和控制系统12b以与压缩机保护和控制系统12相似的方式运作。这样,在先已经详细描述了涡旋传感器72和电机温度传感器74。
在电箱28b内设置有转子传感器76b,从而使转子传感器76b从压缩机10的内部空间22移除。转子传感器76b包括紧密啮合密封终端组件98的束块116和探测由电机32引出的电流的电流传感器118。
束块116包括侧面与中心主体122相接的一对臂120,如图13中所示。臂120和中心主体122的每一个都包括从那里延伸的高压线88。此外,主体122包括从那里延伸用于接收和传输来自传感器组件66b的信号的一对低压线96,在下面将进一步描述。如图13中所示,束块116紧密啮合密封终端组件98,从而每个高压线98都啮合高压管脚102,低压线96啮合低压管脚104。这样,束块116有效地将高压电力线88和低压传感器线96连接到设置在压缩机10内的传感器系统66a和电机32。
电流传感器118靠近束块116设置,如图14中所示。电流传感器76b包括一系列的单独传感元件124,每个单独传感元件都具有通过其延伸的高压线88。传感器元件124探测通过每个高压线88流动的电流并产生表示其的信号。将由传感元件124产生的信号发送到处理电路68b,以将该被感应的电流与阈值极限相比较,并确定电机32是在“锁定转子状态”还是其他故障情况。
如果处理电路68b确定通过高压线88流动的电流超过了所述阈值极限,则处理电路68b就会给电力中断系统70发送一个信号,以限制给电机32供电并关闭压缩机10。
如前面所讨论的,如果在压缩机10内出现了不希望的情况,处理电路68b给电力中断系统70发送信号,以限制给电机32供电。此外,通过一系列的发光器件(LED)126发光,处理电路68b也给操作者发出警报,提醒在压缩机10内已经发生了系统故障,将在下面进一步讨论。
特别参照图14-18,将详细描述压缩机10和相关的压缩机保护和控制系统12b的操作。如前面所讨论的,涡旋传感器72、电机温度传感器74和转子传感器76b探测压缩机10的操作条件和参数。来自单个传感器72,74,76b的感应信号发送到处理电路68b,以与一套预定压缩机操作参数进行比较。假如处理电路68b确定来自单个传感器72,74,76b的感应参数超过了预定的压缩机操作参数,处理电路68b将警告电力中断系统70以限制给电机32供电,由此关闭压缩机10。
当最初启动压缩机10时,系统为准备模式,如图17中所示。这时,处理电路68b检测任何故障情况。如果检测到了故障情况,则处理电路68b会绕过压缩机的运转模式并使压缩机10进入关闭模式。在关闭模式中,根据所经历的特定故障情况,在没有完全关闭电机32的电力的情况下,压缩机10试图恢复系统。然而,如果所经历的故障情况是明显的故障,则关闭模式会进入停工或无控制相,由此压缩机10将彻底关闭,从而限制电力到达电机32。在这种情况下,压缩机10将一直到处理电路68b指导电力中断系统70限制给电机32供电才进入运转模式。通过限制电力来重启压缩机10经常会消除故障并使压缩机正常操作。
当压缩机10返回到准备模式时,或当压缩机从最初启动且探测到没有故障情况时,压缩机10进入运转模式,如图17和18中所示。压缩机10持续运转,且处理电路68b将使诊断系统112连续记录每个成功运转。一旦获得了十次成功运转,处理电路68b就会清除故障记忆,并重新开始系统。这样,处理电路68b接收来自单个传感器72,74,76b的感应系统参数并当系统情况错误时选择性地关闭压缩机10。此外,处理电路68b还在压缩机10的操作模式过程中通过诊断系统112来收集数据,由此存储和跟踪故障。可以理解到,通过存储和跟踪这些故障,处理电路68b能探测并阻止压缩机10可能未来的缺陷和故障。
当压缩机10在运转模式中时,LED126发出绿光,以表示压缩机10在正常情况下运转,如图18中所示。此外,第二LED126也会发光,以表示接触器110给电机32供电。在探测到故障的情形中,黄色LED126会发光,以表示压缩机10经历了故障且需要注意。如果处理电路68b确定了故障情况是严重的故障,处理电路68b就会指导电力中断系统70限制给压缩机10供电,如前面讨论的。
当电力中断系统70关闭了压缩机10时,红色LED126发光,以警告操作者压缩机由于故障情况已经关闭。这时,绿色“运行”和“接触器”LED126关闭,以表示压缩机10在正常情况下不再运转,且接触器110已经从电力供给脱离。应当注意到,这时,只有发光的LED126是红色警报,表示压缩机10已经关闭且记录了故障。可以理解到,通过使用这种LED126,压缩机保护和控制系统12b可使压缩机10指示何时经历了故障情况,从而可以采取适当的行动,如图18中所示。
一般来说,LED警报分为供给电力警报和压缩机警报。通过使用指定的LED闪烁次数来表示特定的警报,可将供给电力和压缩机警报分别通知给使用者。具体地说,供给电力警报包括运转线圈延迟(闪烁一下),错相(闪烁两次),反相(闪烁三次),焊接的接触器(闪烁四次),低压(闪烁五次)和没有三相电(闪烁六次)。压缩机警报包括低油压(闪烁一次),排放温度(闪烁两次),电机温度(闪烁三次),锁定转子(闪烁四次),电机过载(闪烁五次)和断开的热敏电阻器(闪烁六次)。因此,使用者通过简单参照各个LED126很容易确定各个故障情况。
特别参照图19-20,将详细描述压缩机保护和控制系统12的第四个实施方案。考虑到与压缩机保护和控制系统12以及压缩机保护和控制系统12c相关组件在结构上和功能上的大致相似性,在这里和附图中使用相同的参考数字来表示相同的组件。
特别参照图19,复杂的压缩机10c显示为包括一般圆柱形的具有一对焊接帽16c,18c和多个腿20c的密封壳14c。帽16c,18c安装到壳14c,从而确定了压缩机10的内部空间22c。此外,电箱28c固定地连接到一般在帽16c,18c之间的壳14c,并支撑那里的一部分保护系统12c,将在下面进一步讨论。
机轴30c通过电机32c相对于壳14c旋转驱动。电机32包括由密封壳14c固定支撑的定子34c、经过定子34c的线圈36c、以及压力安装到机轴30c上的转子38。电机32c和相关的定子34c、线圈36c和转子38c相对于壳14c驱动机轴30c,由此压缩流体。
复杂的压缩机10c还包括一对驱动涡旋元件40c,每一个在其上表面都具有螺旋叶片或缠绕42c,用于接收和压缩流体。欧式联轴节44c设置在驱动涡旋元件40c和支撑外壳46c之间,并键入驱动涡旋元件40c和非驱动涡旋元件48c。欧式联轴节44用于将机轴30c的旋转力传给驱动涡旋元件40c,从而压缩位于驱动涡旋元件40c和非驱动涡旋元件48c之间的流体。欧式联轴节44c及其与驱动涡旋元件40c和非驱动涡旋元件48c的交互作用优选为受让人共同拥有的U.S.专利No.5,320,506中公开的类型,其内容在这里结合作为参考。
非驱动涡旋元件48c也包括设置成与驱动涡旋元件40c的缠绕42c啮合结合的缠绕50c。非驱动涡旋元件48c具有设置在中心的排放通路52c,其与向上的开放凹口54c相通。凹口54c用于存储位于内部空间22c相对端部的压缩流体,从而第一凹口54c靠近帽16c设置,第二凹口54c靠近帽18c设置。
多个压缩机10c优选为在受让人共同拥有的U.S.专利No.6,672,846和在2003年6月20日提交的公开为U.S.2004-0258542A1的U.S.专利申请No.10/600,106中公开的类型,其公开内容在这里结合作为参考。
对于涡旋传感器72和电机温度传感器74,压缩机保护和控制系统12c以与压缩机保护和控制系统12b相似的方式运作。这样,前面已经详细描述了涡旋传感器72和电机温度传感器74。
在电箱28c内设置有转子传感器76c,从而使电机32c的电流在进入壳14之前被感应。转子传感器76c大致与传感器76b相同,但其需要三个额外的传感元件124来处理由电机32c引出的额外电流。具体地说,因为多个压缩机10c相对于一对非驱动涡旋元件48c驱动一对驱动涡旋元件40c,所以需要较大的电机32c,因而引出了更多的电流。升高的电力需求使得在密封终端组件98和电机32c之间延伸额外的高压线88。这样,转子传感器76c需要总共六个传感元件124来容纳额外的高压线88。
图21和22显示了处理电路68c和转子传感器76c的透视图。六个传感元件124显示为靠近高压线88,因而可监控由电机32c引出的电流。此外,显示了多个传感器输入,例如油面输入134、电机温度传感器输入部136、排放温度输入部138,140、警报继电器140、电力输入142和接触器输入144。此外,通信口112c用于与外部网络连通,将在下面进一步讨论。可以理解到,根据特定的应用,输入可以改变,将大大依赖于压缩机10c内设置的传感器系统66c。例如,如果在压缩机10c内使用涡旋传感器72,则可添加涡旋温度输入146,如图21中所示。
特别参照图23,压缩机10和相关的压缩机保护和控制系统12显示为结合进网络128。尽管已经参照压缩机10和压缩机保护和控制系统12b描述了网络128,但应当理解到,压缩机10c和其他的保护和控制系统12,12a,12c可类似地用在这样的网络中。网络128包括系统控制器138和多个压缩机10。每个压缩机10都通过通信口132与系统控制器130通信。通信部132可连接到诊断部112,从而由在诊断部112中的处理电路68b记录的故障被供给到通信口132和系统控制器130。这样做,可记录并输入每个单个压缩机10经历的故障,从而可在每个压缩机10上进行适当的维护。尽管压缩机保护和控制系统12b已经被描述结合进网络128,但应当理解到,压缩机保护和控制系统12可类似地进入这种网络,同样考虑在本发明的范围内。
如上所述,压缩机保护和控制系统12及压缩机保护和控制系统12b给压缩机10提供了探测并传感系统参数,通过使用LED126来警报潜在故障和通过诊断部112存储故障的能力。此外,在锁定转子情况的情形中,每个电流传感器76,76b都给系统提供了探测由电机32引出的电流的能力,而不仅仅依赖于感应的电机温度。可以理解到,通过感应引出的电流,而不用等待产生和分析温度信号,系统12,12a,12b,12c提供了较快的响应时间,由此提高了压缩机10的生产力和性能。
实际上描述仅仅是示范性的,因而在本发明的范围内可做变化,其没有脱离本发明的精神和范围。
Claims (21)
1.一种压缩机,包括:
至少一个电流传感器;和
处理电路,所述处理电路与所述至少一个电流传感器通信并且能够操作以当所述压缩机引出的电流为峰值锁定转子电流的至少百分之四十时给出锁定转子情况。
2.如权利要求1所述的压缩机,其中所述处理电路确定所述峰值锁定转子电流的安培数为在所述压缩机启动后预定时长期间所获的最高电流读数。
3.如权利要求2所述的压缩机,其中所述预定时长大致等于100毫秒。
4.如权利要求1所述的压缩机,进一步包括与所述处理电路通信的电力中断系统,如果确定了所述锁定转子情况,则所述处理电路指令所述电力中断系统限制供给到所述压缩机的电力。
5.如权利要求1所述的压缩机,其中当确定了所述锁定转子情况时,所述处理电路发出警报。
6.如权利要求1所述的压缩机,其中当确定了预定数量的锁定转子情况后,所述处理电路发出警报。
7.如权利要求1所述的压缩机,其中当在一系列电流转换器输入的任一个中压缩机命令输入被读取为高且达预定时长,则所述处理电路能够操作以确定没有三相电警报。
8.如权利要求7所述的压缩机,其中所述预定时长为大致2秒。
9.如权利要求7所述的压缩机,其中如果在电流转换器输入的任一个中检测到电流或所述压缩机命令输入被读取为低且达所述预定时长,则重设所述警报。
10.如权利要求1所述的压缩机,其中所述处理电路给诊断输出发送诊断信号以记录锁定转子故障。
11.一种方法,包括:
启动压缩机的电机;
在所述启动后的第一预定时长内记录所述电机引出的电流;
将所述电机在所述第一预定时长期间引出的最高电流与所述电机在所述第一预定时长后引出的运行电流进行比较;以及
当所述运行电流超过所述最高电流至少百分之四十时给出锁定转子情况。
12.如权利要求11所述的方法,其中在所述第一预定时长内记录所述电流包括对所述电流进行记录持续大约100毫秒。
13.如权利要求11所述的方法,进一步包括如果所述最高电流超过门槛值,则在所述启动之后的第二预定时长后读取所述电机引出的所述电流。
14.如权利要求13所述的方法,其中所述门槛值大致等于300安培。
15.如权利要求13所述的方法,其中所述第二预定时长大致为800毫秒。
16.如权利要求13所述的方法,进一步包括如果在所述第二预定时长之后所述运行电流超过所述最高电流,则给出所述电机被卡住。
17.如权利要求16所述的方法,进一步包括如果检测到所述卡住,则切断所述电机的电力。
18.如权利要求11所述的方法,进一步包括如果所述最高电流小于门槛值,则在所述启动之后的第二预定时长后读取所述电机引出的所述电流。
19.如权利要求18所述的方法,其中所述门槛值大致等于300安培。
20.如权利要求18所述的方法,其中所述第二预定时长大致为800毫秒。
21.如权利要求18所述的方法,进一步包括如果在所述第二预定时长之后所述运行电流不小于所述最高电流的大致百分之四十,则切断所述电机的电力。
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Also Published As
Publication number | Publication date |
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US20100111709A1 (en) | 2010-05-06 |
US20050196285A1 (en) | 2005-09-08 |
EP1700067A4 (en) | 2007-09-05 |
EP1768237A3 (en) | 2007-08-29 |
US7648342B2 (en) | 2010-01-19 |
US7491034B2 (en) | 2009-02-17 |
ES2518965T3 (es) | 2014-11-06 |
CN101713397B (zh) | 2014-07-09 |
CN100576703C (zh) | 2009-12-30 |
US8475136B2 (en) | 2013-07-02 |
CN1830131A (zh) | 2006-09-06 |
WO2005065355A3 (en) | 2006-04-27 |
EP1700067A2 (en) | 2006-09-13 |
US20060222507A1 (en) | 2006-10-05 |
US20060182635A1 (en) | 2006-08-17 |
WO2005065355A2 (en) | 2005-07-21 |
EP1768237A2 (en) | 2007-03-28 |
EP1700067B1 (en) | 2014-07-30 |
US20130156607A1 (en) | 2013-06-20 |
US7290989B2 (en) | 2007-11-06 |
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