CN102435028A - 压缩机数据模块 - Google Patents

压缩机数据模块 Download PDF

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CN102435028A
CN102435028A CN201110349785XA CN201110349785A CN102435028A CN 102435028 A CN102435028 A CN 102435028A CN 201110349785X A CN201110349785X A CN 201110349785XA CN 201110349785 A CN201110349785 A CN 201110349785A CN 102435028 A CN102435028 A CN 102435028A
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compressor
data module
data
refrigeration system
diagnosis
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CN102435028B (zh
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亨格·M·范
纳加拉杰·贾扬蒂
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Copeland LP
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Emerson Climate Technologies Inc
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B15/00—Systems controlled by a computer
    • G05B15/02—Systems controlled by a computer electric
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
    • F04C18/02—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents
    • F04C18/0207—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form
    • F04C18/0215—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form where only one member is moving
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C23/00—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids
    • F04C23/008—Hermetic pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B49/00—Arrangement or mounting of control or safety devices
    • F25B49/005—Arrangement or mounting of control or safety devices of safety devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2270/00—Control; Monitoring or safety arrangements
    • F04C2270/07—Electric current
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2270/00—Control; Monitoring or safety arrangements
    • F04C2270/19—Temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2270/00—Control; Monitoring or safety arrangements
    • F04C2270/70—Safety, emergency conditions or requirements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2270/00—Control; Monitoring or safety arrangements
    • F04C2270/80—Diagnostics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C27/00—Sealing arrangements in rotary-piston pumps specially adapted for elastic fluids
    • F04C27/005—Axial sealings for working fluid
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/06—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids specially adapted for stopping, starting, idling or no-load operation

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Air Conditioning Control Device (AREA)
  • Control Of Positive-Displacement Pumps (AREA)

Abstract

一种用于制冷系统的数据模块，制冷系统包括系统控制器和压缩机，数据模块包括壳体、处理器和存储器，处理器接收检测数据、将检测数据存储在存储器中并能够操作以将检测数据通信到与制冷系统相关的诊断和控制模块，诊断和控制模块与数据模块分开并且能够操作以诊断制冷系统和压缩机中的至少一个。一种系统，包括：数据模块，数据模块包括处理器和存储器，处理器接收制冷系统和压缩机中的至少一个的检测数据，存储器存储检测数据；和计算机，计算机与数据模块通信并且能够操作以接收来自数据模块的检测数据，计算机相对于数据模块远程定位并且基于检测数据诊断制冷系统和压缩机中的至少一个。

Description

压缩机数据模块
本申请是申请日为2007年9月7日、申请号为200780032977.X的中国专利申请(对应于PCT申请号：PCT/US2007/019563和PCT申请日：2007年9月7日)的分案申请。
相关申请的交叉引用
本申请要求2006年9月7日提交的美国临时专利申请No.60/842,898及2007年9月6日提交的美国专利申请No.11/850,846的优先权。将上述申请的公开内容通过参考引入本文。
技术领域
本公开涉及压缩机，且更明确而言，涉及一种与压缩机一起使用的数据模块。
背景技术
该部分的陈述仅提供了涉及本公开的背景信息并且不构成现有技术。
压缩机用于各种工业及住宅应用中，以使制冷剂在制冷器、热泵、HVAC(采暖通风与空调)或者冷却器系统(通称为“制冷系统”)内循环，从而提供所希望的制热和/或制冷效果。在前述应用中的任一种中，压缩机应当提供始终如一的且有效的操作，从而确保特定制冷系统适当地操作。
制冷系统以及相关的压缩机可包括保护装置，该保护装置间歇地限制供给至压缩机的动力，以便在情况不适宜时防止制冷系统的压缩机以及相关部件(即蒸发器，冷凝器等)的操作。例如，当压缩机内检测到特定的故障或失效时，保护装置可限制供给至压缩机的功力，以防止压缩机和制冷系统在这些状况下操作。
可能导致保护产生的故障类型包括电气故障、机械故障和系统故障。电气故障典型地对与压缩机相关的电机具有直接影响，而机械故障通常包括轴承故障或元件破损。机械故障常常使压缩机内的工作部件的温度升高，并由此导致压缩机失灵，并可能损坏压缩机。
除了与压缩机相关的电气故障及机械故障之外，制冷系统部件可能被系统故障所影响，该系统故障归因于诸如系统内的流体具有不利的液位之类的系统状况或者归因于压缩机外部的流量阻塞状况。这种系统状况会使内部压缩机温度或者压力升高到较高的程度，从而损坏压缩机并导致系统失效和/或出现故障。为了防止系统及压缩机损坏或故障，当出现前面提到的情况中的任一种时，就要通过保护系统关闭压缩机。
传统保护系统可检测温度和/或压力参数作为离散开关，并且在超过预定温度或压力阈值时，中断供给至压缩机电机的动力。这种系统通常利用多个温度和压力传感器来检测压缩机的操作参数，这导致保护系统复杂而昂贵。
由于传统保护系统直接控制它们所依赖的压缩机，因此传统保护系统不能与多个控制模块一起使用，并且仅能与单个压缩机和单个控制器一起使用。
发明内容
一种压缩机，包括机壳、压缩机构、电机、数据模块和压缩机控制器。所述数据模块包括处理器和存储器。所述压缩机控制器包括处理器和存储器。所述数据模块接收检测数据、将检测数据存储在所述存储器中并将检测数据传送到所述压缩机控制器。所述压缩机控制器基于所述检测数据控制所述压缩机的容量并能够操作以便与制冷系统的系统控制器通信。
一种用于制冷系统的数据模块，所述制冷系统包括与关联于压缩机的压缩机控制器通信的系统控制器，所述数据模块包括壳体、处理器和存储器。所述壳体能够安装在所述压缩机上，所述处理器接收检测数据、将检测数据存储到所述存储器中并且能够操作以便将检测数据传送到所述压缩机控制器。
一种压缩机控制系统，包括：压缩机和压缩机控制器，所述压缩机控制器能够操作以便诊断和/或控制所述压缩机。数据模块与所述压缩机相关联并与所述压缩机控制器通信，所述数据模块接收表示压缩机性能的传感器数据。所述数据模块进一步确定非测量系统操作参数并基于所述传感器数据和所述非测量系统操作参数中的至少一个诊断所述压缩机。所述数据模块进一步将所述传感器数据、所述非测量系统操作参数和所述诊断传送到所述压缩机控制器。
一种方法，包括：将传感器数据传送到数据模块；在所述数据模块处处理所述传感器数据以确定压缩机和制冷系统中的至少一个的非测量操作参数；在所述数据模块处处理所述传感器数据和所述确定的非测量操作参数中的至少一个以诊断所述压缩机和制冷系统中的至少一个。所述方法进一步包括将所述传感器数据、所述非测量操作参数和所述诊断传送到系统控制器。在所述系统控制器处基于所述接收到的传感器数据确定所述非测量操作参数，并且在所述系统控制器处基于所述接收到的传感器数据和所述确定的非测量操作参数确定所述诊断。在所述系统控制器处将所述接收到的非测量操作参数与所述确定的非测量操作参数进行比较，并且在所述系统控制器处将所述接收到的诊断与所述确定的诊断相比较。
一种方法，包括：将传感器数据传送到数据模块以及在所述数据模块处处理所述传感器数据以确定压缩机和制冷系统中的至少一个的非测量操作参数。在所述数据模块处处理所述传感器数据和所述非测量操作参数中的至少一个以诊断所述压缩机和制冷系统中的至少一个。将所述传感器数据、所述非测量操作参数和所述诊断中的至少一个存储在所述数据模块的存储器中。将所述传感器数据、所述非测量操作参数和所述诊断中的至少一个传送到第一压缩机控制器。用第二压缩机控制器替换所述第一压缩机控制器。将所述存储的传感器数据、所述存储的非测量操作参数和所述存储的诊断中的至少一个传送到所述第二压缩机控制器。
通过于此提供的说明，进一步的应用领域将会变得清楚。应当理解的是，说明书以及具体示例仅出于解释目的并且并不意欲限制本公开内容的范围。
附图说明
于此所述的附图仅出于说明的目的，并不意欲以任何方式限制本公开内容的范围。
图1是根据本教示原理的集成有数据模块的压缩机的立体图；
图2是图1的压缩机的截面图；
图3是集成有图1的压缩机的制冷系统的示意图；
图4是示出了用于确定多个压缩机和系统操作参数的多个传感器组合的图表；
图5是压缩机电流-冷凝器温度的曲线图，其用于确定给定蒸发器温度下的冷凝器温度；
图6是排气温度-蒸发器温度的曲线图，其用于确定给定冷凝器温度下的蒸发器温度；
图7是排气过热-吸气过热的图表，其用于确定给定室外/环境温度下的吸气过热；
图8是图1示出的数据模块与诊断和控制模块以及多个传感器通信的示意图；
图9是图1的数据模块的更详细的示意图；和
图10是与图1的压缩机一起使用的另一数据模块的示意图，其集成有诊断和控制模块并与多个传感器通信。
具体实施方式
下列说明实质上仅为示例性的且无意限制本公开、应用或用途。应该理解，贯穿全部附图，相同的附图标记表示相同或相应的元件和特征。如这里所用的那样，术语“模块”指的是专用集成电路(ASIC)、电子电路、执行一个或多个软件或固件程序的处理器(共用的、专用的或成组的)和存储器、组合逻辑电路、或提供所述功能性的其它适当的部件。
参照附图，压缩机10示出为集成有保护和控制系统12。保护和控制系统12利用一系列传感器和从传感器获得的信息中导出的非测量操作参数，以诊断压缩机10和压缩机10所关联的制冷系统11。保护和控制系统12包括数据模块14以及诊断和控制模块15。数据模块14可提供被诊断和控制模块15在诊断和控制压缩机10和/或制冷系统11中使用的多级数据。例如，数据模块14可提供被诊断和控制模块15使用的三级数据，包括传感器数据、非测量操作参数(即，处理过的传感器数据)以及被诊断和控制模块15在诊断和控制压缩机10和/或制冷系统11中使用的诊断信息。
数据模块14提供的数据并不是控制器专用的。因此，数据模块14可与任何控制模块一起使用。向数据模块14提供可与任何控制模块一起使用的能力使得数据模块14具有灵活性，因为该数据模块14可与各种制造商和各种构造的各种控制器一起使用。
具体参考图1和2，压缩机10显示成包括大致呈圆柱体形的密封机壳17，该密封机壳17在顶部处具有焊盖16，在底部处具有包括多个焊接的脚20的基座18。盖16及基座18装配到机壳17，从而限定了压缩机10的内部容积22。盖16设有排气管接头24，而机壳17同样设有进气管接头26，该进气管接头26通常布置在盖16与基座18之间，如图2中最佳所示。此外，电气外壳28固定连接于机壳17，通常位于盖16和基座18之间，并且将保护和控制系统12的一部分支撑在其中。
电机32以可旋转的方式相对于机壳17驱动机轴30。电机32包括由密封机壳17以固定方式支撑的定子34、穿过定子的绕组36以及压配合在机轴30上的转子38。电机32和相关的定子34、绕组36以及转子38协作，以相对于机壳17驱动机轴30，从而压缩流体。
压缩机10还包括动涡旋构件40，其上表面上具有螺旋叶片或者涡卷42，用于接收和压缩流体。十字滑环44通常设置在动涡旋构件40与轴承壳46之间，并且通过键连接到动涡旋构件40和静涡旋构件48。十字滑环44将来自机轴30的旋转力传送到动涡旋构件40，以便压缩通常位于动涡旋构件40与静涡旋构件48之间的流体。十字滑环44及其与动涡旋构件40和静涡旋构件48的相互作用优选地是在受让人共同拥有的美国专利No.5,320,506中公开的类型，将该专利的公开内容通过参考引入本文。
静涡旋构件48也包括涡卷50，该涡卷50定位成与动涡旋构件40的涡卷42啮合接合。静涡旋构件48具有居中布置的排气通道52，该通道52与向上开口的凹处54连通。凹处54与由盖16和隔板56所限定的排气管接头24流体连通，从而使得压缩流体经由排气通道52、凹处54以及接头24离开机壳17。静涡旋构件48设计成能够以例如在受让人共同拥有的美国专利No.4,877,382以及5,102,316中公开的适当方式安装到轴承壳46，这些专利的公开内容通过参考引入本文。
电气外壳28包括下部壳体58、上部壳体60和空腔62。下部壳体58通过多个柱头螺栓64安装到机壳17，柱头螺栓64焊接到或者以其它方式固定连接到机壳17。上部壳体60以匹配的方式被下部壳体58所接收，并且在其间限定了空腔62。空腔62定位在压缩机10的机壳17上，并且可用于容纳保护和控制系统12的各个部件和/或用于控制压缩机10和/或制冷系统11操作的其它硬件。
具体参考图2，压缩机10包括致动组件65，该致动组件65使动涡旋构件40与静涡旋构件48选择性地分开，以调节压缩机10的容量。致动组件65可包括连接到动涡旋构件40的螺线管66和连接到螺线管66的控制器68，该控制器68用于控制螺线管66在伸出位置及缩回位置之间的移动。
螺线管66到伸出位置的移动使动涡旋构件40的涡卷42与静涡旋构件48的涡卷50分开，从而减少压缩机10的输出。相反，螺线管66到缩回位置的移动使动涡旋构件40的涡卷42移动靠近静涡旋构件48的涡卷50，从而增大压缩机的输出。由此，可以根据需要或者响应于故障状况来调节压缩机10的容量。
尽管螺线管66到伸出位置的移动描述成使动涡旋构件40的涡卷42与静涡旋构件48的涡卷50分开，但是螺线管66到伸出位置的移动能够交替地使动涡旋构件40的涡卷42移动成与静涡旋构件48的涡卷50接合。同样，尽管螺线管66到缩回位置的移动描述成使动涡旋构件40的涡卷42移动靠近静涡旋构件48的涡卷50，然而螺线管66到缩回位置的移动能够交替地使动涡旋构件40的涡卷42移动远离静涡旋构件48的涡卷50。致动组件65优选地是在受让人共同拥有的美国专利No.6,412,293中公开的类型，该专利的公开内容通过参考引入本文。
具体参考图3，制冷系统11包括冷凝器70、蒸发器72以及通常布置在冷凝器70与蒸发器72之间的膨胀装置74。制冷系统11还包括与冷凝器70相关联的冷凝器风扇76以及与蒸发器72相关联的蒸发器风扇78。冷凝器风扇76与蒸发器风扇78均可为变速风扇，其能够基于制冷系统11的制冷和/或制热需要进行控制。此外，冷凝器风扇76与蒸发器风扇78均可由保护和控制系统12进行控制，从而使得冷凝器风扇76和蒸发器风扇78的操作能够与压缩机10的操作协调。
在操作中，压缩机10使制冷剂大致在冷凝器70和蒸发器72之间循环，从而产生希望的制热和/或制冷效果。压缩机10通常在进气管接头26处接收来自于蒸发器72的蒸汽制冷剂，并且在动涡旋构件40与静涡旋构件48之间压缩蒸汽制冷剂，以便在排气管接头24处以排气压力输出蒸汽制冷剂。
一旦压缩机10已将蒸汽制冷剂充分压缩到排气压力，排气压力下的制冷剂就在排气管接头24处离开压缩机10，并且在制冷系统11内行进到冷凝器70。一旦蒸汽进入到冷凝器70中，制冷剂从气相改变为液相，从而释放热量。通过冷凝器风扇76产生的经由冷凝器70的空气循环将释放的热量从冷凝器70移除。当制冷剂从气相充分改变为液相时，制冷剂离开冷凝器70，并在制冷系统11内大致朝膨胀装置74和蒸发器72行进。
在从冷凝器70排出后，制冷剂首先遇到膨胀装置74。一旦膨胀装置74使液体制冷剂充分膨胀，液体制冷剂就进入蒸发器72，从液相改变为气相。一旦处于蒸发器72内，液体制冷剂就吸收热量，由此从液体变为蒸汽，并产生制冷效果。如果蒸发器72布置在建筑物内部，则希望的制冷效果就通过蒸发器风扇78循环到建筑物中，以冷却建筑物。如果蒸发器72与热泵制冷系统相关联，则蒸发器72可定位在远离建筑物的位置，从而使制冷效果流失到大气中，并将冷凝器70所经历的释放热量引导到建筑物的内部，以加热建筑物。在任一配置中，一旦制冷剂已从液相充分变为气相，则汽化的制冷剂就被压缩机10的进气管接头26所接收，以重新开始循环。
具体参考图2和3，保护和控制系统12显示成包括电流传感器80、温度传感器82、液体管线温度传感器84以及室外/环境温度传感器86。保护和控制系统12还包括分别与数据模块14以及诊断和控制模块15相关联的处理电路88、89，以及动力中断系统90。处理电路88、89和动力中断系统90可布置在安装于压缩机10的机壳17上的电气外壳28内(图2)。传感器80、82、84、86协作，以向数据模块14的处理电路88提供表示压缩机和/或制冷系统操作参数的传感器数据，这些数据被处理电路88用来确定压缩机10和/或制冷系统11的操作参数，这些参数并不由传感器直接测量(下文中称之为“非测量操作参数”)。处理电路88可利用传感器数据来计算非测量操作参数。
处理电路88可利用传感器数据和/或非测量操作参数来诊断压缩机10和/或制冷系统11。数据模块14可将传感器数据、导出的非测量操作参数和/或压缩机/制冷系统诊断信息传送到诊断和控制模块15的处理电路89，供处理电路89在诊断和控制压缩机10和/或制冷系统11时使用。由于数据模块14提供压缩机和/或制冷系统操作数据，因此数据模块14并不是控制器专用的，并可与包括诊断和控制模块15的各种控制模块一起使用。将在下面详细说明数据模块14以及诊断和控制模块15的操作。
电流传感器80可提供与例如压缩机机械故障、电机故障之类的高压侧故障以及例如缺相、反相、电机绕组电流失调、开路、低压、转子电流锁定、电机绕组温度过高、接触器焊接或开路和短期循环之类的电气部件故障有关的诊断信息。电流传感器80可监测压缩机电流和电压，用于确定并区分机械故障、电机故障和电气部件故障。
电流传感器80可安装在电气外壳28内，或者作为选择地集成到压缩机10的机壳17内(图2)。在任一情况下，电流传感器80可监测压缩机10消耗的电流，并产生表示该电流的信号，例如在受让人共同所有的美国专利No.6,615,594、于2004年12月30日提交的美国专利申请No.11/027,757以及于2005年2月16日提交的美国专利申请No.11/059,646中所公开的那样，这些专利及专利申请的公开内容通过参考引入本文。
在公开了电流传感器80的同时，保护和控制系统12还可包括安装在排气压力区中的排气压力传感器92和/或安装在压缩机机壳17内或者附近例如排气管接头24内(图2)或诸如冷凝器70之类的外部系统中(图3)的温度传感器94。温度传感器94可以另外地或者作为选择地沿通常在压缩机10与冷凝器70之间延伸的管道103(图3)设置在压缩机10外部并可以设置成紧靠冷凝器70的进口。前述传感器中的任一个或者全部可以与电流传感器80结合使用，以便向保护和控制系统12提供额外的系统信息。
温度传感器82通常提供与例如制冷剂的低充注量、节流口堵塞、蒸发器风扇故障或者压缩机10泄漏之类的低压侧故障有关的数据。温度传感器82可设置成临近压缩机10的排气管接头24或者排气通道52，并且可监测离开压缩机10的压缩流体的排气管线温度。除了前面所述之外，温度传感器82可设置在压缩机机壳17的外部，并位于排气管接头24附近，从而使得处于排气压力的蒸汽能够遇到温度传感器82。将温度传感器82定位在机壳17外部并通过向温度传感器82提供容易适于与实践中的任意压缩机和任意系统一起使用的能力，使得压缩机和系统的设计具有灵活性。
在温度传感器82可提供排气管线温度信息的同时，保护和控制系统12还可包括吸气压力传感器96或者低压侧温度传感器98，可将所述传感器安装在压缩机10的进口附近。在一种构型中，吸气压力传感器96或低压侧温度传感器98可定位在进气管接头26附近(图2)或者安装在诸如蒸发器72之类的外部系统中(图3)。吸气压力传感器96和低压侧温度传感器98可以另外地或者作为选择地沿着通常在蒸发器72和压缩机10之间延伸的管道105(图3)设置，并且可以设置在紧靠蒸发器72的出口的位置处。前述传感器中的任一个或者全部可以与温度传感器82结合使用，以便向保护和控制系统12提供额外的系统信息。
尽管温度传感器82可定位在压缩机10的机壳17的外部，但是类似地能够在压缩机10的机壳17内测量压缩机10的排气温度。可使用通常在排气管接头24处获得的排气中心温度代替图2中所示的排气管线温度设置。密封终端组件100可以与这种内部排气温度传感器一起使用，从而维持压缩机机壳17的密封特性。
液体管线温度传感器84可定位在冷凝器70内或者沿着通常在冷凝器70的出口与膨胀装置74之间延伸的管道102定位。在这一点上，温度传感器84定位在制冷系统11内代表液体位置的位置中，在制冷系统11是热泵的情况下，所述液体位置为制冷模式和制热模式所共有。由于液体管线温度传感器84通常设置在冷凝器70的出口附近，或者沿着通常在冷凝器70的出口与膨胀装置74之间延伸的管道102设置，因此液体管线温度传感器84遇到液体制冷剂(即，制冷剂已经在冷凝器70内从蒸汽变为液体之后)，并由此能够将液体制冷剂的温度表示提供给处理电路88。尽管液体管线温度传感器84描述成位于冷凝器70的出口附近或者沿着在冷凝器70和膨胀装置74之间延伸的管道102上，但液体管线温度传感器84可以位于制冷系统11内的任意位置，所述任意位置使得液体管线温度传感器84能够将制冷系统11内的液体制冷剂的温度表示提供给处理电路88。
室外/环境温度传感器86可定位在压缩机机壳17的外部，并且通常提供压缩机10和/或制冷系统11周围的室外/环境温度的表示。室外/环境温度传感器86可设置在压缩机机壳17附近，从而使得室外/环境温度传感器86紧靠处理电路88(图2和3)。将室外/环境温度传感器86紧靠压缩机机壳17设置为数据模块14的处理电路88提供了大致位于压缩机10附近的温度测量。将室外/环境温度传感器86紧靠压缩机机壳17设置不仅为处理电路88提供了压缩机10周围的周围空气的准确测量，而且还使得室外/环境温度传感器86能够附连或布置在电气外壳28内。
数据模块14的处理电路88可接收来自于电流传感器80、温度传感器82、液体管线温度传感器84以及室外/环境温度传感器86的传感器信息。如图4中所示，处理电路88利用来自于各个传感器80、82、84、86的传感器数据以确定压缩机10和/或制冷系统11的非测量操作参数。
处理电路88能够基于来自于各个传感器80、82、84、86的传感器数据来确定压缩机10和/或制冷系统11的非测量操作参数，而无需针对每个非测量操作参数的单独的传感器。处理电路88能够确定冷凝器温度(Tcond)、制冷系统11的过冷、冷凝器温度与室外/环境温度之间的温度差(TD)，以及制冷系统11的排气过热。
处理电路88可通过参考压缩机映射上的压缩机功率来确定冷凝器温度。所导出的冷凝器温度一般是饱和的冷凝器温度，其等同于特定制冷剂的排气压力。冷凝器温度应当接近冷凝器70的中点处的温度。由于冷凝器盘管可能包含许多不同温度的平行回路，因此当与通过安装到冷凝器70的盘管上的温度传感器提供的冷凝器温度值相比时，利用压缩机映射来确定冷凝器温度提供了冷凝器70的全面温度的更准确的表示。
图5是压缩机映射的示例，其示出了在各种蒸发器温度(Tevap)下的压缩机电流对冷凝器温度。如所示，电流保持相当的恒定而与蒸发器温度无关。由此，尽管准确的蒸发器温度能够通过二次多项式(即，二次函数)来确定，但是出于控制的目的，蒸发器温度可以通过一次多项式(即，线性函数)来确定，并且能够近似为约45、50或55华氏度。当确定冷凝器温度时，与选择不正确的蒸发器温度有关的误差是最小的。尽管所示为压缩机电流，但是可利用压缩机功率和/或电压代替确定冷凝器温度中所使用的电流。如电流传感器80所示的那样，可以基于电机32消耗的电流确定压缩机功率。
一旦得知压缩机电流，可以基于压缩机映射中所包含的基线电压来调整电压。可以使用如图5中所示的曲线图，通过比较压缩机电流与冷凝器温度来确定冷凝器温度。在受让人共同所有的、于2005年2月16日提交的美国专利申请No.11/059,646中描述了上述用于确定冷凝器温度的过程，该申请的公开内容通过参考引入本文。
一旦得知冷凝器温度，处理电路88随后就能够通过从冷凝器温度中减去由液体管线温度传感器84指示的液体管线温度并随后减去表示压缩机10的出口与冷凝器70的出口之间的压降的附加的小值(通常为2-3°F)来确定制冷系统11的过冷。处理电路88由此不仅能够确定冷凝器温度，而且能够确定制冷系统11的过冷，而无需针对任一操作参数的额外的温度传感器。
处理电路88还能够计算冷凝器70与制冷系统11周围的室外/环境温度之间的温度差(TD)。处理电路88可通过对照图5所示的曲线图参考压缩机10消耗的功率或电流来确定冷凝器温度，而无需将温度传感器设置在冷凝器70内。一旦得知(即，导出)冷凝器温度，处理电路88就能够通过从所导出的冷凝器温度中减去从室外/环境温度传感器86接收的环境温度来确定温度差(TD)。
一旦得知冷凝器温度，也就同样能够确定出制冷系统11的排气过热。具体地，处理电路88可通过从排气管线温度中减去冷凝器温度来确定制冷系统11的排气过热。如上所述，可通过温度传感器82检测排气管线温度，并将其提供给处理电路88。由于处理电路88能够对照如图5所示的曲线图通过参考压缩机功率来确定冷凝器温度，并且由于处理电路88基于从温度传感器82接收的信息知晓了排气管线温度，因此处理电路88能够通过从排气管线温度中减去冷凝器温度来确定压缩机10的排气过热。
一旦确定排气过热，处理电路88能够通过参考如图7所示的曲线来确定吸气过热。具体地，可通过对照室外/环境温度传感器86所指示的环境温度参考排气过热来确定吸气过热。
一旦确定冷凝器温度，处理电路88能够参考如图6中所示的曲线、基于从温度传感器82接收的排气温度信息来确定准确的蒸发器温度。一旦得知了冷凝器温度和蒸发器温度，处理电路88就能够随后确定压缩机容量和流量。
除了导出冷凝器温度、蒸发器温度、过冷、排气过热、压缩机容量和流量以及吸气过热以外，处理电路88同样可以测量或估算冷凝器风扇76和/或蒸发器风扇78的风扇功率，并导出用于确定制冷系统11的效率和蒸发器72的容量的压缩机功率因子。冷凝器风扇76和/或蒸发器风扇78的风扇功率可通过与风扇76、78相关联的传感器85直接测量，或可由处理电路88估算。
一旦确定非测量操作参数，就能够通过数据模块14确定压缩机10和制冷系统11的性能。如上所述，数据模块14可将三级数据提供到诊断和控制模块15。首先，传感器数据从数据模块14传送到诊断和控制模块15，被诊断和控制模块15用于诊断和控制压缩机10和制冷系统11。其次，传感器数据和/或非测量操作参数可被传送到诊断和控制模块15，被诊断和控制模块15用于诊断和控制压缩机10和制冷系统11。再次，传感器数据、非测量操作参数和压缩机/制冷系统诊断信息可被传送到诊断和控制模块15，被诊断和控制模块15用于诊断和控制压缩机10和/或制冷系统11。
除了上述三级数据以外，数据模块14可包括配置数据和故障历史数据。配置数据可包括压缩机序列号、生产日期、压缩机性能映射等，而故障历史数据可包括压缩机和/或制冷系统以前经历的故障的列表，以及特定故障的有关原因。可将配置数据和故障历史数据提供到诊断和控制模块15，以更新诊断和控制模块15，或在应该替换诊断和控制模块15的情况下，配置新的诊断和控制模块15。例如，在诊断和控制模块15出现故障并且安装新的诊断和控制模块15的情况下，数据模块14可将配置和/或故障历史数据提供到新的诊断和控制模块15，以配置该诊断和控制模块15。这种配置和故障历史数据可包括在受让人共同拥有的于2005年4月26日提交的美国临时专利申请No.60/674781，现为于2006年4月14日提交的美国专利申请No.11/405021中所描述的数据，所述专利和专利申请的公开内容通过参考引入本文。
具体参照图8和9，将详细描述数据模块14以及诊断和控制模块15的操作。如图8中所示，数据模块14接收来自各种传感器80、82、84、86的输入，这些传感器向数据模块14提供了压缩机10和/或制冷系统11的当前操作状况。数据模块14的处理电路88可利用来自相应的传感器80、82、84、86的数据来确定压缩机10和/或制冷系统11的非测量操作参数。
如上所述，数据模块14可确定压缩机10和/或制冷系统11的非测量操作参数，例如过冷、冷凝器温度、冷凝器温度差、吸气过热、排气过热和蒸发器温度。例如，数据模块14可接收来自液体管线温度传感器84的液体管线温度信息和来自电流传感器80的电流和/或电压信息，并可利用从相应的传感器80、84接收的信息确定冷凝器温度和过冷(图4)。具体而言，一旦通过从电流传感器80接收到的信息得知电机32消耗的电流，数据模块14的处理电路88就可对照例如图5所示的曲线之类的可存储在电流模块14内的压缩机映射参照从电流传感器80读取的电流。对照例如图5所示曲线之类的压缩机映射参照电机32消耗的电流并通过对照近似的蒸发器温度参照电机32消耗的电流可得到近似的冷凝器温度。一旦通过处理电路88确定冷凝器温度，就可如图4中所示，简单地通过从确定的冷凝器温度中减去由液体管线温度传感器84测量到的液体管线温度来确定过冷。
一旦数据模块14的处理电路88已确定压缩机10和/或制冷系统11的非测量参数，数据模块14就可随后将从传感器80、82、84、86接收到的传感器数据中的一个或两个以及导出的非测量参数传送到诊断和控制模块15。诊断和控制模块15的处理电路89可利用来自传感器80、82、84、86的传感器数据和/或导出的非测量参数诊断压缩机10和/或制冷系统11。
这些诊断信息可用于区分压缩机10和/或制冷系统11的各种故障状况，并可用于控制/保护压缩机10和/或制冷系统11。例如，诊断和控制模块15可利用从数据模块14接收的数据控制压缩机10的容量。诊断和控制模块15可通过经由螺旋管66将动涡旋构件40与静涡旋构件48选择性地分离开、通过选择性地在开启状态和关闭状态之间触发压缩机、和/或通过阻塞吸气调节来调节压缩机容量。
除了简单地将从传感器80、82、84、86接收到的传感器数据和非测量参数传送到诊断和控制模块15以外，数据模块14还可利用从传感器80、82、84、86接收到的传感器数据和/或非测量参数来诊断压缩机10和/或制冷系统11。具体而言，数据模块14的处理电路88可利用从传感器80、82、84、86接收到的传感器数据和非测量参数向诊断和控制模块15提供压缩机10和/或制冷系统11的诊断信息。
除了前述以外，作为替换，数据模块14可将压缩机10和/或制冷系统11的诊断信息直接提供到诊断和控制模块15的处理电路89，用于直接控制压缩机10和/或制冷系统11的操作。
诊断和控制模块15可使用数据模块14提供的诊断信息与诊断和控制模块15的处理电路89作出的压缩机10和/或制冷系统11的诊断信息相比较。以此方式，诊断和控制模块15能够通过将处理电路89作出的诊断信息与处理电路88提供的诊断信息相比较来验证处理电路89作出的诊断。
除了将来自传感器80、82、84、86的传感器数据、非测量操作参数以及压缩机10和/或制冷系统11的诊断信息传送到诊断和控制模块15之外，数据模块14可另外地或作为替换地将这些传感器数据、非测量操作参数和/或诊断信息直接供应到诸如计算机或系统控制器104和/或手持装置106之类的外部系统。诊断和控制模块15还可向计算机104和/或手持装置106提供从数据模块14接收到的传感器数据、非测量操作参数和/或诊断信息以及由诊断和控制模块15执行的诊断，供计算机104和/或手持装置106使用。
计算机104和/或手持装置106可利用传感器数据、非测量操作参数和/或诊断信息来控制、追踪和/或监测压缩机10和/或制冷系统11的操作。例如，计算机104可远离压缩机10和/或制冷系统11定位，从而可以从远程位置诊断、控制和监测压缩机10和/或制冷系统11。向手持装置106提供传感器数据、非测量操作参数和/或由数据模块14和/或诊断和控制模块15所执行的诊断为维修技术人员提供了压缩机10和/或制冷系统11的操作历史，供维护压缩机10和/或制冷系统11时使用。
如图8中所示，数据模块14和相关的处理电路88可与诊断和控制模块15以及相关的处理电路89分开。例如，数据模块14和相关的处理电路88可设置在电气外壳28内，以便将数据模块14和相关的处理电路88安装在压缩机10的机壳17上，而诊断和控制模块15以及相关的处理电路89可远离压缩机10定位。将诊断和控制模块15远离数据模块14定位允许对压缩机10和/或制冷系统11进行遥控。
尽管诊断和控制模块15可远离数据模块14定位，但是作为替换，诊断和控制模块15可接收在电气外壳28中，从而将诊断和控制模块15以及相关的处理电路89安装于压缩机10的机壳17。图2示出了数据模块14和相关的处理电路88及诊断和控制模块15以及相关的处理电路89大致布置于电气外壳28内并安装于压缩机10的机壳17。图10示意性示出了该关系，从而数据模块14与诊断和控制模块15可整合为单个单元。尽管数据模块14与诊断和控制模块15描述为分别包括单独的处理电路88、89，但当数据模块14与诊断和控制模块15集成到电气外壳28中时，数据模块14与诊断和控制模块15可共享处理电路。
尽管数据模块14与诊断和控制模块15均接收在压缩机10的电气外壳28内，但将诊断和控制模块15与数据模块14分开以便诊断和控制模块15远离数据模块14和压缩机10定位，允许数据模块14与各种诊断和控制模块一起使用。由于数据模块14主要用作集线器，用于接收传感器数据和用于确定压缩机和/或制冷系统的非测量操作参数，因此数据模块14实质上可与任何诊断和控制模块15一起使用。
最初的设备制造商通常使用不同的诊断和控制模块以及配置。因此，可互换的并可与任何诊断和控制模块15一起使用的数据模块14使得集成有这种数据模块14的压缩机10能够实质上与任何诊断和控制模块15一起使用。
本领域技术人员现在可通过上述内容了解到，可以各种形式实施本公开的广泛教示。因此，尽管已经结合其具体示例描述了该公开内容，但是由于在研究了附图、说明书及所附的权利要求书之后，其它变型对于本领域技术人员将变得明显，因此不应将本公开内容的真实范围如此限定。

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1.一种用于制冷系统的数据模块，所述制冷系统包括系统控制器和压缩机，所述数据模块包括壳体、处理器和存储器，所述处理器接收检测数据、将检测数据存储在所述存储器中并能够操作以将所述检测数据通信到与所述制冷系统相关的诊断和控制模块，所述诊断和控制模块与所述数据模块分开并且能够操作以诊断所述制冷系统和所述压缩机中的至少一个。
2.如权利要求1所述的数据模块，其中所述诊断和控制模块与计算机和手持装置中的至少一个通信。
3.如权利要求1所述的数据模块，其中所述诊断和控制模块将诊断通信至计算机和手持装置中的至少一个。
4.如权利要求1所述的数据模块，进一步包括计算机和手持装置中的至少一个，计算机和手持装置中的所述至少一个能够操作以监测所述压缩机和所述制冷系统中的至少一个的操作。
5.如权利要求1所述的数据模块，进一步包括计算机和手持装置中的至少一个，计算机和手持装置中的所述至少一个能够操作以向维修技术人员提供所述制冷系统和所述压缩机中的至少一个的操作历史。
6.如权利要求1所述的数据模块，其中所述诊断和控制模块基于来自所述数据模块的所述检测数据确定所述压缩机和所述制冷系统中的至少一个的至少一个非测量操作参数。
7.如权利要求6所述的数据模块，其中所述至少一个非测量操作参数包括过冷、冷凝器温度差、吸气过热和排气过热。
8.如权利要求1所述的数据模块，其中所述诊断和控制模块将诊断通信至所述系统控制器。
9.一种系统，包括：
数据模块，所述数据模块包括处理器和存储器，所述处理器接收制冷系统和压缩机中的至少一个的检测数据，所述存储器存储所述检测数据；和
计算机，所述计算机与所述数据模块通信并且能够操作以接收来自所述数据模块的所述检测数据，所述计算机相对于所述数据模块远程定位并且基于所述检测数据诊断所述制冷系统和所述压缩机中的至少一个。
10.如权利要求9所述的系统，其中所述数据模块安装在所述制冷系统的部件上。
11.如权利要求9所述的系统，其中所述数据模块安装在所述压缩机上。
12.如权利要求9所述的系统，其中所述计算机控制和监测所述制冷系统和所述压缩机中的至少一个。
13.如权利要求9所述的系统，其中所述数据模块诊断所述制冷系统和所述压缩机中的至少一个。
14.如权利要求9所述的系统，其中所述数据模块与手持装置通信。
15.如权利要求14所述的系统，其中所述数据模块将所述检测数据、所述制冷系统的非测量操作参数以及诊断中的至少一个通信至所述手持装置。
16.如权利要求9所述的系统，其中所述制冷系统包括系统控制器。
17.如权利要求16所述的系统，其中所述系统控制器与所述计算机通信。
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