CN104131978A - 变速压缩机保护系统和方法 - Google Patents

变速压缩机保护系统和方法 Download PDF

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CN104131978A
CN104131978A CN201410312784.1A CN201410312784A CN104131978A CN 104131978 A CN104131978 A CN 104131978A CN 201410312784 A CN201410312784 A CN 201410312784A CN 104131978 A CN104131978 A CN 104131978A
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compressor
temperature
control module
speed
saturated
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CN104131978B (zh
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亨格·M·范
史蒂芬·M·塞贝尔
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Copeland LP
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Emerson Climate Technologies Inc
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    • 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
    • F04C28/28—Safety arrangements; Monitoring
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/06—Cooling; Heating; Prevention of freezing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
    • F04B39/123—Fluid connections
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • 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
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    • 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
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    • F04C28/24—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by using valves controlling pressure or flow rate, e.g. discharge valves or unloading valves
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    • F25B49/00—Arrangement or mounting of control or safety devices
    • F25B49/02—Arrangement or mounting of control or safety devices for compression type machines, plants or systems
    • F25B49/022—Compressor control arrangements
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    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2203/00—Motor parameters
    • F04B2203/02—Motor parameters of rotating electric motors
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    • F04B2203/02—Motor parameters of rotating electric motors
    • F04B2203/0209—Rotational speed
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    • F04C2210/227—Steam
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F04C2210/26—Refrigerants with particular properties, e.g. HFC-134a
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    • F04C2240/40—Electric motor
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
    • Y02B30/70—Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T137/00—Fluid handling
    • Y10T137/8593—Systems
    • Y10T137/85978—With pump
    • Y10T137/85986—Pumped fluid control

Abstract

一种用于压缩机的系统和方法可包括连接至压缩机的变频驱动器，其接收电功率并通过调制该电功率的频率来调制压缩机的速度。连接至变频驱动器的控制模块监控来自变频驱动器的压缩机功率数据和压缩机速度数据，并且基于该压缩机功率数据和该压缩机速度数据计算与该压缩机相关联的制冷系统的饱和冷凝器温度。

Description

变速压缩机保护系统和方法
本申请是申请人艾默生环境优化技术有限公司的申请日为2008年10月8日、国家申请号为200880110785.0(国际申请号为PCT/US2008/011596)、发明名称为“变速压缩机保护系统和方法”的专利申请的分案申请。
相关申请的交叉引用
本申请要求2008年10月7日提交的美国实用新型申请No.12/246,959和2007年10月8日提交的美国临时申请No.60/978,258的权益。将上述申请的全部公开内容以参引的方式结合于此。
技术领域
本公开涉及压缩机，更具体来说，涉及一种用于与变速压缩机一起使用的保护系统。
背景技术
本部分的陈述仅提供与本公开相关的背景信息并可不构成现有技术。
压缩机可用在多种工业和住宅应用中，以便在制冷装置、热泵、供暖通风和空调(HVAC)或冷却机系统(统称“制冷系统”)内循环制冷剂，从而提供所期望的加热或冷却效应。在任一种前述应用中，压缩机应该提供一致且有效的运行以确保特定的应用(即，制冷装置、热泵、HVAC或冷却机系统)正确地运行。变速压缩机可用于根据制冷系统负载来改变压缩机容量。
压缩机在回液情况过程中的运行是不希望的。在过多的液态制冷剂流到压缩机中时，会发生回液状况。严重的回液会稀释油并降低其润滑性能，导致可能的咬死。尽管压缩机中液态制冷剂和润滑油的一些混合可能是期望的，但过度的混合可能导致损坏压缩机。
同样，压缩机在过高温度水平下的运行可能损坏压缩机。过热状况可能损坏包括例如电动马达的内部压缩机部件。
发明内容
提供一种系统，包括：压缩机；连接至所述压缩机的变频驱动器，所述变频驱动器接收电功率并通过调制所述电功率的频率来调制所述压缩机的速度；连接至所述变频驱动器的控制模块，所述控制模块监控来自所述变频驱动器的压缩机功率数据和压缩机速度数据，并且基于所述压缩机功率数据和所述压缩机速度数据计算与所述压缩机相关联的制冷系统的饱和冷凝器温度。
在其它特征中，所述排气温度传感器可输出排气温度信号，所述排气温度信号对应于离开所述压缩机的制冷剂的排气温度，其中，所述控制模块接收所述排气温度信号并基于所述排气温度信号和所述饱和冷凝器温度来计算与所述压缩机相关联的排气过热温度。
在其它特征中，所述控制模块可基于所述计算出的排气过热温度监控所述压缩机的过热状况和回液状况中的至少一个。
在其它特征中，所述控制模块可访问所述压缩机的压缩机映射数据，所述压缩机映射数据使所述压缩机的功率和速度数据与同所述压缩机相关联的预期的饱和冷凝器温度有相互关系，其中，所述控制模块基于所述压缩机映射数据来确定所述饱和冷凝器温度。
在其它特征中，所述控制模块可基于所述计算出的排气过热温度来调整所述压缩机的所述速度和与所述压缩机相关联的膨胀阀中的至少一个。
在其它特征中，所述控制模块可调整所述压缩机的所述速度和所述膨胀阀以将所述压缩机的运行维持在预定的运行包络线内，所述预定的运行包络线包括最大回液界限、最大排气过热度界限、最大排气温度界限、最小排气过热度界限、最小排气温度界限、最大涡旋温度界限和最大马达温度界限中的至少一个。
在其它特征中，所述控制模块可通过执行第一函数和第二函数的多次迭代来计算所述饱和冷凝器温度和饱和蒸发器温度，所述第一函数使所述饱和冷凝器温度与压缩机功率、压缩机速度和所述饱和蒸发器温度相关联，并且所述第二函数使所述饱和蒸发器温度与所述排气温度、所述压缩机速度和所述饱和冷凝器温度相关联。
在其它特征中，所述控制模块可基于所述饱和蒸发器温度、所述饱和冷凝器温度和所述压缩机速度数据来计算所述压缩机的压缩机容量和压缩机效率中的至少一个。
提供了一种方法，该方法可包括：通过变频驱动器将电功率输送至压缩机，所述变频驱动器构造成通过调制输送至所述压缩机的所述电功率的频率来调制所述压缩机的速度；监控来自所述变频驱动器的压缩机功率数据和压缩机速度数据；基于所述压缩机功率数据和所述压缩机速度数据来计算与所述压缩机相关联的制冷系统的饱和冷凝器温度。
在其它特征中，该方法可包括接收来自排气温度传感器的排气温度信号，所述排气温度信号对应于离开所述压缩机的制冷剂的排气温度，并基于所述排气温度信号和所述饱和冷凝器温度来计算与所述压缩机相关联的排气过热温度。
在其它特征中，该方法可包括基于所述计算出的排气过热温度监控所述压缩机的过热状况和回液状况中的至少一个。
在其它特征中，该方法可包括访问所述压缩机的压缩机映射数据，所述压缩机映射数据使所述压缩机的功率和速度数据与同所述压缩机相关联的预期的饱和冷凝器温度相关联，其中，基于所述压缩机映射数据来计算所述饱和冷凝器温度。
在其它特征中，该方法可包括基于所述计算出的排气过热温度来调整所述压缩机的所述速度和与所述压缩机相关联的膨胀阀中的至少一个。
在其它特征中，可将所述压缩机的所述速度和所述膨胀阀调整成将所述压缩机的运行维持在预定运行包络线内，所述预定的运行包络线包括最大回液界限、最大排气过热度界限、最大排气温度界限、最小排气过热度界限、最小排气温度界限、最大涡旋温度界限和最大马达温度界限中的至少一个。
在其它特征中，该方法可包括通过执行第一函数和第二函数的多次迭代来计算所述饱和冷凝器温度和饱和蒸发器温度，所述第一函数使所述饱和冷凝器温度与压缩机功率、压缩机速度和饱和蒸发器温度相关联，并且所述第二函数使所述饱和蒸发器温度与所述排气温度、所述压缩机速度和所述饱和冷凝器温度相关联。
在其它特征中，该方法可包括基于所述饱和蒸发器温度、所述饱和冷凝器温度和所述压缩机速度数据来计算所述压缩机的压缩机容量和压缩机效率中的至少一个。
一种系统可包括：压缩机；吸气温度传感器，所述吸气温度传感器输出吸气温度信号，所述吸气温度信号对应于进入所述压缩机的制冷剂的温度；连接至所述压缩机的变频驱动器，所述变频驱动器接收电功率并通过调制所述电功率的频率来调制所述压缩机的速度；冷源温度传感器，所述冷源温度传感器输出冷源温度信号，所述冷源温度信号对应于与所述变频器相关联的冷源的温度；连接至所述变频驱动器的控制模块，所述控制模块接收所述吸气温度信号，监控来自所述变频驱动器的压缩机功率数据和压缩机速度数据，并基于所述吸气温度信号、所述冷源温度信号、所述压缩机功率数据和所述压缩机速度数据来计算与所述压缩机相关联的制冷系统的饱和蒸发器温度、所述制冷系统中的制冷剂的质量流量以及与所述压缩机相关联的吸气过热度中的至少一个。
在其它特征中，吸气温度传感器可位于压缩机的入口处。
在其它特征中，吸气温度传感器可位于变频驱动器的入口处。
在其它特征中，所述控制模块可基于所述压缩机速度数据和所述压缩机功率数据来计算变频器热量损失。
在其它特征中，控制模块可基于变频器热损失、吸气温度信号和冷源温度信号来计算制冷剂的质量流量。
在其它特征中，所述控制模块可基于所述压缩机功率数据、所述压缩机速度数据以及所述质量流量来计算所述饱和蒸发器温度。
在其它特征中，所述控制模块可基于所述吸气温度信号和所述饱和蒸发器温度来计算吸气过热温度。
在其它特征中，所述控制模块可基于所述计算出的吸气过热温度来监控所述压缩机的过热状况与回液状况中的至少一个。
在其它特征中，环境温度传感器可输出与环境温度相对应的环境温度信号，其中，所述控制模块接收所述环境温度信号并基于所述环境温度信号和所述计算出的吸气过热温度来计算排气过热度。
在其它特征中，一种方法可包括：接收来自吸气温度传感器的吸气温度信号，所述吸气温度信号对应于进入压缩机的制冷剂的温度；通过变频驱动器将电功率输送至所述压缩机，所述变频驱动器构造成通过调制所述电功率的频率来调制所述压缩机的速度；接收来自冷源温度传感器的冷源温度信号，所述冷源温度信号对应于与所述变频器相关联的冷源的温度；监控来自所述变频驱动器的压缩机功率数据和压缩机速度数据；基于所述吸气温度信号、所述冷源温度信号、所述压缩机功率数据和所述压缩机速度数据来计算与所述压缩机相关联的制冷系统的饱和蒸发器信号、所述制冷系统中的制冷剂的质量流量和与所述压缩机相关联的吸气过热度中的至少一个。
在其它特征中，该方法可包括基于所述压缩机速度数据和所述压缩机功率数据来计算变频器热量损失。
在其它特征中，该方法可包括基于所述变频器热量损失、所述吸气温度信号和所述冷源温度信号来计算所述制冷剂的所述质量流量。
在其它特征中，该方法可包括基于所述压缩机功率数据、所述压缩机速度数据和所述质量流量来计算所述饱和蒸发器温度。
在其它特征中，该方法可包括基于所述吸气温度信号和所述饱和蒸发器温度来计算吸气过热温度。
在其它特征中，该方法可包括基于所述饱和吸气过热温度来监控所述压缩机的过热状况和回液状况中的至少一个。
在其它特征中，该方法可包括接收来自环境温度传感器的环境温度信号，所述环境温度信号对应于环境温度，以及基于所述环境温度信号和所述计算出的吸气过热温度来计算排气过热度。
本申请的其它方面将通过于此提供的说明而变得显而易见。应该理解的是，该说明和具体示例仅出于说明性的目的，并不意于限制本公开的范围。
附图说明
于此所述附图仅出于说明性的目的，并不意于以任何方式限制本公开的范围。
图1是制冷系统的示意图。
图2是带有变频驱动器的压缩机的立体图。
图3是带有变频驱动器的压缩机的另一立体图。
图4是压缩机的截面图。
图5是示出了与吸气过热度和室外温度有相互关系的排气过热度的曲线图。
图6是示出了与压缩机功率和压缩机速度有相互关系的冷凝器温度的曲线图。
图7是示出了压缩机的运行包络线的曲线图。
图8是示出了与蒸发器温度和对于给定压缩机速度的压缩机功率有相互关系的冷凝温度的曲线图。
图9是示出了与蒸发器温度和冷凝器温度有相互关系的排气管线温度的曲线图。
图10是示出了制冷系统的导出数据的流程图。
图11是制冷系统的示意图。
图12是示出了制冷系统的导出数据的流程图。
图13是示出了与变频驱动器热量损失有相互关系的质量流量的曲线图。
图14是示出了与变频器效率有相互关系的变频器速度的曲线图。
图15是示出了带有测量到的输入量和导出的输出量的控制模块的曲线图。
图16是制冷系统的示意图。
图17是压缩机的截面图。
具体实施方式
下列说明实质上仅为示例性的，并不意于限制本公开、申请或用途。应该理解的是，在所有附图中，对应的附图标记指代相似或对应的部件或特征。
当在这里使用时，术语模块、控制模块和控制器可以指的是下列各项中的一个或多个：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、专用的或组的)和存储器、组合逻辑电路或提供所述功能的其它适当的部件。当在这里使用时，计算机可读介质可指能够存储包括处理器的计算机或模块的数据的任何介质。计算机可读介质包括，但不限于，存储器、随机存储器(RAM)、只读存储器(ROM)、可编程只读存储器(PROM)、电可擦可编程只读存储器(EEPROM)、闪存、光盘只读存储器(CD-ROM)、软盘、磁带、其它磁性介质、光学介质、或能够存储计算机的数据的任何其它装置或介质。
参照图1，示例性的制冷系统5包括压缩制冷剂蒸汽的压缩机10。尽管在图1中示出了具体的制冷系统，但本教导可应用于包括热泵、HVAC和冷冻机系统的任一制冷系统。来自压缩机10的制冷剂蒸汽被输送至冷凝器12，在冷凝器12处，制冷剂蒸汽在高压下液化，从而将热量排至外部空气。离开冷凝器12的液态制冷剂经过膨胀阀14被输送至蒸发器16。膨胀阀14可以是机械阀或电子阀，用于控制制冷剂的过热。制冷剂通过膨胀阀14，在膨胀阀14处，压降导致高压液态制冷剂获得低压的液体和蒸汽的混合体。当热空气移过蒸发器16时，低压液体转变为气体，从而将热量从蒸发器16移走。低压气体被再次输送至压缩机10，在压缩机10处，它被压缩至高压气体，并被输送至冷凝器12以再次开始制冷循环。
参照图1、2和3，压缩机10可由容置在机壳20中的还称之为变频驱动器(VFD)的变频驱动器22驱动。机壳22可靠近压缩机10。变频驱动器22接收来自电源18的电功率并将电功率输送至压缩机10。变频驱动器22包括控制模块25，该控制模块25带有能够操作以调制并控制输送至压缩机10的电动马达的电功率频率的软件和处理器。控制模块25包括用于存储数据的计算机可读介质，该数据包括由处理器执行用以调制和控制输送至压缩机的电动马达的电功率频率的软件和控制模块25执行和进行本教导的保护和控制算法所必需的软件。通过调制输送至压缩机10的电动马达的电功率频率，控制模块25可由此调制和控制压缩机10的速度并由此控制压缩机10的容量。
变频驱动器22包括固态电子设备，以调制电功率的频率。一般来说，变频驱动器22将输入的电功率从交流电(AC)转换至直流电(DC)，并随后将电功率从DC转换回至期望频率下的AC。例如，变频驱动器22可利用全波整流桥来直接整流电功率。变频驱动器22可随后利用绝缘栅双极型晶体管(IGBT)或闸流晶体管来斩断电功率以获得所期望的频率。可使用其它适当的电子部件来调制来自电源18的电功率的频率。
压缩机10的电动马达速度由从变频驱动器22接收的电功率的频率控制。例如，当以六十赫兹的电功率驱动压缩机10时，压缩机10可以以全容量运行的方式运行。当以三十赫兹的电功率驱动压缩机10时，压缩机10可以半容量运行的方式运行。
从蒸发器16至压缩机10的管路可被确定路线成经过机壳20，以冷却机壳20内的变频驱动器22的电子部件。机壳20可包括冷板15。吸入的气态制冷剂可在进入压缩机10之前冷却该冷板，并由此冷却变频驱动器22的电子部件。这样，冷板15可起到吸入气体与变频驱动器22之间的热交换器的作用，从而在吸入气体进入压缩机10以前，将来自变频驱动器22的热量转移给吸入气体。
如图2和3中所示，来自容置在机壳20内的变频驱动器22的电功率可经由附连至压缩机10的终端盒24而被输送至压缩机10。
压缩机回液或过热状况是不期望的，并且可导致损坏压缩机10或其它制冷系统部件。吸气过热度(SSH)和/或排气过热度(DSH)可与压缩机的回液或过热状况有相互关系，并可被监控以检测和/或预测压缩机10的回液或过热状况。DSH是离开压缩机的制冷剂蒸汽的温度(称之为排气管线温度(DLT))与饱和冷凝器温度(Tcond)之差。吸气过热度(SSH)是进入压缩机的制冷剂蒸汽的温度(称之为吸气管线温度(SLT))与饱和蒸发器温度(Tevap)之差。
如图5中所示，SSH与DSH可以是有相互关系的。DSH与SSH之间的相互关系对于涡旋型压缩机而言，可能是特别精确的，其中外部环境温度仅是次要影响。如图5中所示，示出了针对室外温度(ODT)为115华氏度、95华氏度、75华氏度和55华氏度的DSH与SSH之间的相互关系。图5中所示的相互关系仅是一种示例，并且针对特定压缩机的特定相互关系可因压缩机类型、型号、容量等而变化。
回液状况可在SSH接近零度或DSH接近20至40华氏度时发生。为此，DSH可用于检测回液状况的开始及其严重程度。当SSH处于零度时，SSH不会指示回液状况的严重程度。当回液状况变得更加严重时，SSH保持在零度附近。但是，当SSH处于零度时，DSH可在20至40华氏度之间，并可更准确地指示回液状况的严重程度。当DSH处于30华氏度至80华氏度的范围中时，压缩机10可在正常范围内运行。当DSH低于30华氏度时，回液状况的开始可能发生。当DSH低于10华氏度时，可能发生严重的回液状况。
就过热而言，当DSH高于80华氏度时，过热状况的开始可能发生。当DSH大于100华氏度时，可能存在严重的过热状况。
在图5中，示出了针对示例性的制冷剂充注水平的典型的SSH温度。例如，当制冷系统5中的制冷剂充注百分比降低时，SSH典型地增加。
可从Tcond中减去DLT来确定DSH。DLT可由DLT传感器28感测，该DLT传感器28感测离开压缩机10的制冷剂的温度。如图1中所示，DLT传感器28可位于压缩机10的外部，并可安装在压缩机10的排气口附近。作为替代，可如图4中所示使用内部DLT传感器30。在图4中，示出了压缩机10的截面。内部DLT传感器30可嵌在涡旋压缩机的上部静涡盘中，并可感测离开互相啮合的涡盘的排出制冷剂的温度。
在替代方案中，可使用组合温度/压力传感器。在这种情况下，可基于由组合传感器所测量的离开压缩机10的制冷剂的压力来测量Tcond。此外，在这种情况下，可基于由传感器的温度部分测量的DLT并基于由该组合传感器的压力部分测量的Tcond来计算DSH。
Tcond可通过其它系统参数得到。具体来说，Tcond可通过压缩机电流和电压(即，压缩机功率)、压缩机速度和与压缩机10相关联的压缩机映射数据得到。在申请号为11/059,646、公开号为U.S.2005/0235660的共同转让的美国申请“Compressor Diagnostic and Protection System”中描述了一种基于定速压缩机的电流、电压和压缩机映射数据来获得Tcond的方法。使得压缩机电流和电压与Tcond有相互关系的定速压缩机的压缩机映射数据可以是压缩机所特有的且基于针对特定的压缩机类型、型号和容量的测试数据。
在变速压缩机的情况下，除压缩机功率以外，Tcond还可以是压缩机速度的函数。
以瓦特为单位的压缩机功率与压缩机速度之间的图示相互关系示于图6中。如所示，Tcond是压缩机功率和压缩机速度的函数。这样，可基于测试数据得到针对特定压缩机的具有使压缩机功率、压缩机速度与Tcond有相互关系的数据的三维压缩机映射。可使用压缩机电流来代替压缩机功率。但是，压缩机功率可能比压缩机电流优选，以降低任一管线电压变化的影响。压缩机映射可存储在控制模块25可访问的计算机可读介质中。
这样，控制模块25可基于压缩机功率数据和压缩机速度数据来计算Tcond。控制模块25可计算、监控、或在计算过程中检测压缩机功率数据，所述计算被执行用以将来自电源18的电功率转换成期望频率下的电功率。这样，对于控制模块25而言，压缩机功率和电流数据是可容易获得的。此外，控制模块25可基于输送至压缩机10的电动马达的电功率频率来计算、监控或检测压缩机速度。这样，对于控制模块25而言，压缩机速度数据同样是可容易获得的。基于压缩机功率和压缩机速度，控制模块25可得到Tcond。
在测量或计算Tcond之后，控制模块25可将DSH计算为Tcond与DLT之差，并且DLT数据接收自外部DLT传感器28或内部DLT传感器30。
控制模块25可基于上述的DSH与回液和过热状态之间的相互关系来监控DSH以检测回液或过热状况。一旦检测到回液或过热状况，控制模块25可相应地调整压缩机速度或调整膨胀阀14。控制模块25可与膨胀阀14通信或控制膨胀阀14。作为替代，控制模块25可与制冷系统5用系统控制器通信，并可将回液或过热状况告知系统控制器。系统控制器随后可相应调整膨胀阀或压缩机速度。
可监控DSH以检测或预测突然的回液或过热状况。在未伴有Tcond的显著改变的情况下，DLT或DSH的突然变化可能指示突然的回液或过热状况。例如，如果DLT或DSH在预定时间段(例如，50秒)内降低预定的温度量(例如50华氏度)，则可能存在突然的回液状况。这种状况可能由于膨胀阀14被卡住在打开位置而导致。同样，在未伴有Tcond的显著改变的情况下，DLT或DSH突然增大相似的幅度可能指示因膨胀阀14被卡住在闭合位置而导致的突然的过热状况。例如，如果DLT或DSH在预定时间段(例如，50秒)内升高预定的温度量(例如50华氏度)，则可能存在突然的过热状况。
控制模块25可监控DSH和DLT以确定压缩机10是否正在预定的运行包络线内运行。如图7中所示，压缩机运行包络线可提供最大回液界限与最大和/或最小DSH/DLT界限。此外，在涡旋压缩机的情况下，可提供最大涡旋温度界限(T涡旋)。此外，可提供最大马达温度(T马达)。如图7中所示，压缩机速度和膨胀阀14可基于DSH和/或DLT进行调整，从而确保压缩机的运行在压缩机运行包络线内。这样，DSH和/或DLT可移回到如图7所示的可接受范围中。压缩机速度调整可优先于膨胀阀调整。在一些情况下，例如除霜状态，对于膨胀阀14而言，可能难以快速响应，因此压缩机速度调整可能更为适当。
如果发生回液状况，那么控制模块25可限制压缩机速度范围。例如，当DSH低于30华氏度时，压缩机运行可限制于压缩机的冷却容量额定速度。例如，冷却容量额定速度可以是4500转/分(RPM)。当DSH在30华氏度与60华氏度之间时，压缩机运行速度范围可线性扩大到整个运行速度范围。例如，压缩机运行速度范围可在1800至7000RPM之间。
使Tcond与压缩机速度和功率有相互关系的函数可以采用预定或恒定的饱和Tevap。如图8中所示，压缩机功率与Tcond之间的相互关系可以不受Tevap变化的影响。
为了额外的精确性，Tevap可以作为Tcond和DLT的函数而得到，如在申请号为11/059,646、美国公开号为2005/0235660的共同转让的美国申请中所述的那样。对于变速压缩机而言，该相互关系还可反映压缩机速度。这样，Tevap可作为Tcond、DLT和压缩机速度的函数而得到。
如图9中所示，对于多种Tcond水平，Tevap被示为与DLT有相互关系。为此，可使用对于不同速度的压缩机映射数据。
可基于单个推导来计算Tcond和Tevap。
此外，可基于如下等式进行迭代计算：
等式1：Tcond＝f(压缩机功率，压缩机速度，Tevap)
等式2：Tevap＝f(Tcond，DLT，压缩机速度)
可执行这些等式的多次迭代来实现收敛。例如，三次迭代可提供最佳收敛。如上所讨论的那样，可利用更多或更少次的迭代或不使用迭代。
也可通过利用针对不同速度、基于DLT和压缩机功率、基于如下等式的压缩机映射数据来确定Tevap和Tcond：
等式3：Tevap＝f(压缩机功率，压缩机速度，DLT)
等式4：Tcond＝f(压缩机功率，压缩机速度，DLT)
一旦获知Tevap和Tcond，就可获得额外的压缩机性能参数。例如，可基于特定压缩机型号和容量的额外压缩机性能映射数据来获得压缩机容量和压缩机效率。这种额外的压缩机映射数据可通过测试数据获得。例如，可根据下列等式来获得压缩机质量流量或容量：
等式5：Tevap＝f(压缩机速度，Tcond，质量流量)
可根据下列等式来获得质量流量：
等式6：
质量流量＝m0+m1*Tevap+m2*Tcond+m3*RPM+
m4*Tevap*Tcond+m5*Tevap*RPM+m6*Tcond*RPM+
m7*Tevap^2+m8*Tcond^2+m9*RPM^2+
m10*Tevap*Tcond*RPM+m11*Tevap^2*Tcond+
m12*Tevap^2*RPM+m13*Tevap^3+m14*Tevap*Tcond^2+
m15*Tcond^2*RPM+m16*Tcond^3+m17*Tevap*RPM^2+
m18*Tcond*RPM^2+m19*RPM^3
其中，m0-m19为压缩机型号和尺寸所特有的，如由压缩机制造商所公开的。
压缩机映射数据可存储在位于控制模块25内的或控制模块25可访问的计算机可读介质内。
如图10中所示，示出了用于导出参数的流程图。在步骤100中，Tcond可通过压缩机功率和压缩机速度获得。在步骤101中，Tevap可通过DLT和Tcond获得。在步骤102中，容积/质量流量和压缩机能效比可通过Tevap和Tcond获得。此外，通过在步骤103中监控运行时间，可获得额外的参数。具体地，在步骤104中，负载和Kwh/天可通过运行时间、容积/质量流量、压缩机能效比和压缩机功率获得。
通过监控上述运行参数，控制模块25可确保压缩机10在由特定的压缩机设计师或制造商预置的可接受的运行包络线界限内运行，并且可检测并预测诸如压缩机回液和过热状况的某些不希望的运行状况。此外，控制模块25可获得与压缩机效率、能耗等相关的其它有用的数据。
在压缩机10由吸气冷却的变频驱动器22所驱动的情况下，作为替代，可计算Tevap。由于Tevap可如上所述通过质量流量、Tcond和压缩机速度进行计算，因此控制模块25可通过进入冷板15的吸入气体的温度(Ts)与位于变频驱动器22上或其附近的冷源的温度(Ti)之间的差获得质量流量。控制模块25可根据下列等式来计算ΔT：
等式7：ΔT＝Ts-Ti
可通过示于图11中的两个温度传感器33和34来测量Ts和Ti。温度传感器33测量冷源的温度(Ti)并可结合为变频驱动器22的一部分。作为替代，温度传感器33可测量离开冷板15的吸入气体的温度，并可位于冷板15与压缩机10之间的管路上或该管路附近。温度传感器34测量进入冷板15的吸入气体的温度。
控制模块25可基于ΔT并通过确定变频驱动器22的施加热量来确定质量流量。如图12中所示，可基于变频驱动器22的损失热和ΔT来获得质量流量。如图13中所示，可基于测试数据来映射质量流量、ΔT和施加的变频器热量之间的关系。
如图14中所示，可基于变频器速度(即，压缩机速度)和变频器效率来获得变频器热量。
再次参照图12，输入量包括压缩机速度(RPM)120、压缩机电流122、压缩机电压124、压缩机功率因数126、Ti128和Ts130。通过压缩机电流122、压缩机电压124和功率因数126，获得压缩机功率132。通过温度Ti128和Ts130，获得ΔT134。通过RPM120和功率，获得Tcond136。同样通过RPM120和功率132，获得变频器热损失138。通过变频器热损失和ΔT134，获得质量流量140。通过RPM120、Tcond136和质量流量140，获得Tevap142。通过Tevap142和Ts130，获得SSH144。通过SSH144和由环境温度传感器29感测到的环境温度，获得DSH146。一旦获得DSH146，就可获得上述算法的所有益处，包括防止压缩机10不出现回液和过热状况。
如由虚线141所示，可迭代地计算Tcond和Tevap，以更为精确地获得Tcond和Tevap。例如，最佳收敛可利用三次迭代实现。还可利用更多或更少次的迭代。
如图15中所示，控制模块25将压缩机速度RPM、变频驱动器电流、电压和功率以及冷源温度Ti和Ts作为测量到的输入量。控制模块还将由环境温度传感器29指示的环境温度作为输入量。如上所讨论的那样，控制模块25通过这些测量到的输入量获得Tcond、Tevap、质量流量、SSH、DSH和DLT的输出量。
如图16中所示，控制模块25可利用SLT传感器35来监控SLT，其可包括组合压力和温度传感器。在这种情况下，可基于由组合传感器的压力部分所测量到的吸气压力来测量Tevap。进一步地，可基于Tevap和由组合传感器的温度部分所测量到的SLT来计算SSH。SLT传感器34、35可位于压缩机10的入口处，并可感测在变频器22、机壳20或冷板15之后，进入压缩机10的制冷剂的温度或压力。作为替代，SLT传感器可位于机壳20、变频器22或冷板15的入口处，并可感测进入机壳20、变频器22或冷板15的制冷剂的温度或压力。
此外，与上述基于DLT计算DSH相似，控制模块25还可计算SSH。例如，压缩机功率、压缩机速度和压缩机映射数据可用于获得Tcond，并且可通过Tcond获得Tevap。一旦获得Tevap，SSH就可通过SLT和Tevap获得，并如上所述用于监控多个压缩机运行参数，并防止回液和过热状况。

Claims (20)

1.一种系统，包括：
连接至冷凝器的压缩机；
排气管线温度传感器，所述排气管线温度传感器输出对应于离开所述压缩机的制冷剂的排气管线温度的排气管线温度信号；
控制模块，所述控制模块连接至所述排气管线温度传感器，所述控制模块确定饱和冷凝器温度，基于所述饱和冷凝器温度和所述排气管线温度计算排气过热温度，通过将所述排气过热温度与预定阈值进行比较来监控所述压缩机的回液状况，并且当所述排气过热温度小于或等于所述预定阈值时，增加所述压缩机的速度或者减小与所述压缩机相关联的膨胀阀的开度。
2.根据权利要求1所述的系统，其中，所述预定阈值为30华氏度。
3.根据权利要求1所述的系统，其中，当所述排气过热温度小于或等于所述预定阈值时，所述控制模块增加所述压缩机的速度。
4.根据权利要求1所述的系统，其中，当所述排气过热温度小于或等于所述预定阈值时，所述控制模块减小所述膨胀阀的开度。
5.根据权利要求1所述的系统，其中，所述控制模块通过判断在预定时间段内所述排气过热温度是否减小了预定量而监控突然的回液状况。
6.根据权利要求1所述的系统，其中，所述控制模块接收对应于离开所述压缩机的制冷剂的排气压力的排气压力信号，并且基于所述排气压力而确定所述饱和冷凝器温度。
7.根据权利要求1所述的系统，其中，所述控制模块接收压缩机功率数据，并且根据所述压缩机功率数据和所述压缩机的速度来确定所述饱和冷凝器温度。
8.根据权利要求1所述的系统，还包括连接至所述压缩机和所述冷凝器的蒸发器，其中，所述控制模块接收压缩机功率数据，根据所述饱和冷凝器温度、所述排气管线温度以及所述压缩机的速度来确定饱和蒸发器温度，并且根据所述压缩机功率数据、所述压缩机的速度以及所述饱和蒸发器温度来确定所述饱和冷凝器温度。
9.根据权利要求8所述的系统，其中，所述控制模块执行确定所述饱和冷凝器温度和所述饱和蒸发器温度的多次迭代以实现收敛。
10.根据权利要求1所述的系统，其中，所述控制模块接收压缩机功率数据，并且根据所述压缩机功率数据、所述压缩机的速度以及所述排气管线温度来确定所述饱和冷凝器温度。
11.一种方法，包括：
利用控制模块来确定连接至压缩机的冷凝器的饱和冷凝器温度；
利用所述控制模块来接收对应于离开所述压缩机的制冷剂的排气管线温度的排气管线温度信号；
利用所述控制模块来基于所述饱和冷凝器温度和所述排气管线温度来计算排气过热温度；
利用所述控制模块通过将所述排气过热温度与预定阈值进行比较而监控所述压缩机的回液状况；以及
当所述排气过热温度小于或等于所述预定阈值时，利用所述控制模块来增加所述压缩机的速度或者减小膨胀阀的开度。
12.根据权利要求11所述的方法，其中，所述预定阈值为30华氏度。
13.根据权利要求11所述的方法，其中，当所述排气过热温度小于或等于所述预定阈值时，所述控制模块增加所述压缩机的速度。
14.根据权利要求11所述的方法，其中，当所述排气过热温度小于或等于所述预定阈值时，所述控制模块减小所述膨胀阀的开度。
15.根据权利要求11所述的方法，还包括利用所述控制模块通过判断在预定时间段内所述排气过热温度是否减小了预定量而监控突然的回液状况。
16.根据权利要求11所述的方法，还包括利用所述控制模块接收对应于离开所述压缩机的制冷剂的排气压力的排气压力信号以及基于所述排气压力确定所述饱和冷凝器温度。
17.根据权利要求11所述的方法，还包括利用所述控制模块接收压缩机功率数据以及根据所述压缩机功率数据和所述压缩机的速度来确定所述饱和冷凝器温度。
18.根据权利要求11所述的方法，还包括利用所述控制模块接收压缩机功率数据，根据所述饱和冷凝器温度、所述排气管线温度以及所述压缩机的速度来确定连接至所述压缩机和所述冷凝器的蒸发器的饱和蒸发器温度，以及根据所述压缩机功率数据、所述压缩机的速度以及所述饱和蒸发器温度来确定所述饱和冷凝器温度。
19.根据权利要求18所述的方法，还包括利用所述控制模块执行确定所述饱和冷凝器温度和所述饱和蒸发器温度的多次迭代以实现收敛。
20.根据权利要求11所述的方法，还包括利用所述控制模块接收压缩机功率数据，以及根据所述压缩机功率数据、所述压缩机的速度以及所述排气管线温度来确定所述饱和冷凝器温度。
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US20130240043A1 (en) 2013-09-19
US10077774B2 (en) 2018-09-18
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US20090090118A1 (en) 2009-04-09
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