EP3126676B1 - Système et procédé de commande d'un compresseur à capacité variable - Google Patents

Système et procédé de commande d'un compresseur à capacité variable Download PDF

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Publication number
EP3126676B1
EP3126676B1 EP15772694.4A EP15772694A EP3126676B1 EP 3126676 B1 EP3126676 B1 EP 3126676B1 EP 15772694 A EP15772694 A EP 15772694A EP 3126676 B1 EP3126676 B1 EP 3126676B1
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EP
European Patent Office
Prior art keywords
capacity
compressor
capacity mode
mode
control module
Prior art date
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Active
Application number
EP15772694.4A
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German (de)
English (en)
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EP3126676A1 (fr
EP3126676A4 (fr
Inventor
Hung M. Pham
Shane J. Angle
Edward J. TRUDEAU
Chetan SOWANI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Copeland LP
Original Assignee
Emerson Climate Technologies Inc
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Publication date
Priority claimed from US14/674,980 external-priority patent/US10371426B2/en
Application filed by Emerson Climate Technologies Inc filed Critical Emerson Climate Technologies Inc
Priority to EP20209391.0A priority Critical patent/EP3800354B1/fr
Publication of EP3126676A1 publication Critical patent/EP3126676A1/fr
Publication of EP3126676A4 publication Critical patent/EP3126676A4/fr
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Publication of EP3126676B1 publication Critical patent/EP3126676B1/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/70—Control systems characterised by their outputs; Constructional details thereof
    • F24F11/80—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air
    • F24F11/83—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling the supply of heat-exchange fluids to heat-exchangers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
    • F24F11/63—Electronic processing
    • F24F11/65—Electronic processing for selecting an operating mode
    • F24F11/67—Switching between heating and cooling modes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/70—Control systems characterised by their outputs; Constructional details thereof
    • F24F11/80—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air
    • F24F11/83—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling the supply of heat-exchange fluids to heat-exchangers
    • F24F11/84—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling the supply of heat-exchange fluids to heat-exchangers using valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/70—Control systems characterised by their outputs; Constructional details thereof
    • F24F11/80—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air
    • F24F11/86—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling compressors within refrigeration or heat pump circuits
    • 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
    • F25B13/00—Compression machines, plants or systems, with reversible cycle
    • 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
    • F25B49/02—Arrangement or mounting of control or safety devices for compression type machines, plants or systems
    • F25B49/022—Compressor control arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/62—Control or safety arrangements characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
    • F24F11/63—Electronic processing
    • F24F11/65—Electronic processing for selecting an operating mode
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F11/00—Control or safety arrangements
    • F24F11/70—Control systems characterised by their outputs; Constructional details thereof
    • F24F11/80—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air
    • F24F11/83—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling the supply of heat-exchange fluids to heat-exchangers
    • F24F11/85—Control systems characterised by their outputs; Constructional details thereof for controlling the temperature of the supplied air by controlling the supply of heat-exchange fluids to heat-exchangers using variable-flow pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
    • F24F2110/00—Control inputs relating to air properties
    • F24F2110/10—Temperature
    • F24F2110/12—Temperature of the outside air
    • 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
    • F25B2313/00—Compression machines, plants or systems with reversible cycle not otherwise provided for
    • F25B2313/007—Compression machines, plants or systems with reversible cycle not otherwise provided for three pipes connecting the outdoor side to the indoor side with multiple indoor units
    • 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
    • F25B2600/00—Control issues
    • F25B2600/01—Timing
    • 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
    • F25B2600/00—Control issues
    • F25B2600/02—Compressor control
    • F25B2600/025—Compressor control by controlling speed
    • F25B2600/0252—Compressor control by controlling speed with two speeds
    • 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
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/21—Temperatures
    • F25B2700/2104—Temperatures of an indoor room or compartment
    • 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
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/21—Temperatures
    • F25B2700/2106—Temperatures of fresh outdoor air

Definitions

  • the present disclosure relates to a climate-control system having a variable-capacity compressor and to a method for controlling a variable capacity compressor.
  • a climate-control system such as, for example, a heat-pump system, a refrigeration system, or an air conditioning system, may include a fluid circuit having an outdoor heat exchanger, an indoor heat exchanger, an expansion device disposed between the indoor and outdoor heat exchangers, and a compressor circulating a working fluid (e.g., refrigerant or carbon dioxide) between the indoor and outdoor heat exchangers. Varying a capacity of the compressor can impact the energy-efficiency of the system and the speed with which the system is able to heat or cool a room or space.
  • a working fluid e.g., refrigerant or carbon dioxide
  • US 2006/0032253 discloses a climate-control system.
  • DE 10 2011 079205 A1 discloses a refrigerator, in particular a domestic refrigerator according to the preamble of claim 1 and a method for operating a compressor according to the preamble of claim 10.
  • a climate-control system according to the invention is disclosed in claim 1; a method for controlling a compressor is disclosed in claim 10.
  • the present invention provides a climate-control system including a variable-capacity compressor unit and a control module controlling the compressor unit.
  • the compressor unit is operable in a first capacity mode and in a second capacity mode that is higher than the first capacity mode.
  • the control module is configured to switch the compressor unit among a shutdown state, the first capacity mode and the second capacity mode based on a demand signal and outdoor-air-temperature data.
  • the control module is configured to switch the compressor unit from the shutdown state to the first capacity mode in response to receipt of the demand signal.
  • the control module is configured to switch the compressor unit from the first capacity mode to the second capacity mode while receiving the same demand signal.
  • the control module may include outdoor-air-temperature-sensing and demand-signal-sensing circuitry.
  • control module receives the demand signal from a single-stage thermostat disposed within a space to be cooled by the climate-control system.
  • the climate-control system may include an indoor heat exchanger receiving working fluid from the compressor unit and a blower forcing air into a convective heat transfer relationship with working fluid in the indoor heat exchanger.
  • the blower may include a fixed-speed motor or a variable-speed motor operable at a selectable fixed speed tap, for example.
  • the control module is configured to switch the compressor unit from the first capacity mode to the second capacity mode if the measured temperature value of the outdoor-air-temperature data is greater than a predetermined temperature value and a previous runtime of the compressor unit in the second capacity mode during a previous demand period exceeds a second predetermined time period. That is, the runtime of the compressor unit in the second capacity mode may be adaptively compared from cycle-to-cycle to a previous runtime in the second capacity mode.
  • control module switches the compressor unit from the first capacity mode to the second capacity modes based on whether the previous runtime was greater than five minutes.
  • the control module is configured to switch the compressor unit from the first capacity mode to the second capacity mode based on whether the compressor unit has been operating in the first capacity mode for greater than a first predetermined time period.
  • the climate-control system includes a comfort control interface configured to be positioned at one of a plurality of comfort level settings.
  • a first one of the comfort level settings may correspond to an energy-efficiency operating mode and a second one of the comfort level settings may correspond to a high-performance operating mode.
  • control module is configured to compare the compressor runtime with a low-capacity runtime threshold and a high-capacity runtime threshold.
  • control module is configured to switch the compressor between the low-capacity mode and the high-capacity mode based on the comparison of the compressor runtime with the first capacity runtime and based on the comparison of the compressor runtime with the second capacity runtime.
  • the low-capacity runtime threshold and the high-capacity runtime threshold are determined based on a selected one of the comfort level settings.
  • the compressor unit includes only one compressor (e.g., a variable-capacity compressor). In other embodiments, the compressor unit could include a plurality of variable-capacity and/or fixed-capacity compressors.
  • the present invention provides a method of controlling a compressor.
  • the compressor is operable in a first capacity mode and in a second capacity mode that is higher than the first capacity mode.
  • the method includes receiving a demand signal, for example from a thermostat; comparing an outdoor air temperature with a predetermined temperature value; and operating the compressor in response to receipt of the demand signal in one of the first and second capacity modes based on the comparison of the outdoor air temperature and the predetermined temperature.
  • the compressor is switched from a shutdown state to the first capacity mode in response to receipt of the demand signal.
  • the method includes switching the compressor from the first capacity mode to the second capacity mode based on whether the compressor has been operating in the first capacity mode for greater than a first predetermined time period.
  • the method includes switching the compressor from the first capacity mode to the second capacity mode while receiving the same demand signal.
  • the method includes switching the compressor from the first capacity mode to the second capacity mode if the measured temperature value of the outdoor air temperature is greater than the predetermined temperature value and a previous runtime of the compressor unit in the second capacity mode during a previous demand period exceeds a second predetermined time period.
  • the second predetermined time period is a previous amount of time over which the compressor previously operated in the second capacity mode spanning from an initiation of the second capacity mode until satisfaction of a previous demand signal.
  • control module is configured to compare the compressor runtime with a first capacity runtime threshold and a second capacity runtime threshold.
  • control module is configured to switch the compressor between the first and second capacity modes based on the comparison of the compressor runtime with the first capacity runtime and based on the comparison of the compressor runtime with the second capacity runtime.
  • the first capacity runtime threshold and the second capacity runtime threshold are determined based on a selected one of the comfort level settings.
  • Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
  • first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
  • spatially relative terms such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures.
  • Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features.
  • the example term “below” can encompass both an orientation of above and below.
  • the device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
  • a system 10 that includes a variable-capacity compressor (or a variable-capacity group of compressors) 12, an outdoor heat exchanger 14, an outdoor blower 15, a first expansion device 16, a second expansion device 17, an indoor heat exchanger 18, and an indoor blower 19.
  • the system 10 is a heat-pump system having a reversing valve 20 operable to control a direction of working fluid flow through the system 10 to switch the system 10 between a heating mode and a cooling mode.
  • the system 10 may be an air-conditioning system or a refrigeration system, for example, and may be operable in only the cooling mode.
  • a control module 22 controls operation of the compressor 12 and switches the compressor 12 between a low-capacity mode (first capacity mode) and a high-capacity (second capacity mode) mode based on data received from an outdoor-air-temperature sensor 24, a signal received from a thermostat 26, a comparison between a runtime T of the compressor 12 and a predetermined low-capacity runtime threshold T1, and a comparison between a previous high-capacity runtime threshold T2 with a predetermined value.
  • the control module 22 may minimize or reduce employment of high-capacity-mode operation to minimize or reduce energy usage while maintaining an acceptable level of comfort within a space to be heated or cooled.
  • the compressor 12 can be or include a scroll compressor, a reciprocating compressor, or a rotary vane compressor, for example, and/or any other type of compressor.
  • the compressor 12 may be any type of variable-capacity compressor that is operable in at least a low-capacity mode and a high-capacity mode.
  • the compressor 12 may be or include a multi-stage compressor, a group of independently operable compressors, a multi-speed or variable-speed compressor (having a variable-speed or multi-speed motor), a compressor having modulated suction (e.g., blocked suction), a compressor having fluid-injection (e.g., an economizer circuit), a pulse-width-modulated scroll compressor configured for scroll separation (e.g., a digital scroll compressor), a compressor having variable-volume-ratio valves configured to leak intermediate-pressure working fluid, or a compressor having two or more of the above capacity modulation means.
  • the compressor 12 could include any other additional or alternative structure for varying its capacity and/or the operating capacity of the system 10.
  • the low-capacity and/or high-capacity modes may be continuous, steady-state operating modes, or compressor 12 may be modulated (e.g., pulse-width-modulated) during operation in the low-capacity mode and/or during operation in the high-capacity mode.
  • Exemplary variable-capacity compressors are disclosed in assignee's commonly owned United States Patent No. 8,616,014 , United States Patent No. 6,679,072 , United States Patent No. 8,585,382 , United States Patent No. 6,213,731 , United States Patent No. 8,485,789 , United States Patent No. 8,459,053 , and United States Patent No. 5,385,453 .
  • the compressor 12, the outdoor heat exchanger 14, the outdoor blower 15, the first expansion device 16 and the reversing valve 20 may be disposed in an outdoor unit 28.
  • the second expansion device 17, the indoor heat exchanger 18 and the indoor blower 19 may be disposed within an indoor unit 30 (e.g., an air handler or furnace) disposed within a home or other building 32.
  • a first check valve 34 may be disposed between outdoor heat exchanger 14 and the first expansion device 16 and may restrict or prevent fluid flow through the first expansion device 16 in the cooling mode and may allow 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 and may restrict or prevent fluid flow through the second expansion device 17 in the heating mode and may allow fluid flow through the second expansion device 17 in the cooling mode.
  • the outdoor-air-temperature sensor 24 is disposed outside of the building 32 and within or outside of the outdoor unit 28 and is configured to measure an outdoor ambient air temperature and communicate the outdoor ambient air temperature value to the control module 22 intermittently, continuously or on-demand.
  • the outside-air-temperature sensor 24 could be a thermometer or other sensor associated with a weather monitoring and/or weather reporting system or entity.
  • the control module 22 may obtain the outdoor-air temperature (measured by the sensor 24) from the weather monitoring and/or weather reporting system or entity via, for example, an internet, Wi-Fi, Bluetooth®, Zigbee®, power-line carrier communication (PLCC), or cellular connection or any other wired or wireless communication protocol.
  • PLCC power-line carrier communication
  • control module 22 may communicate with the weather monitoring and/or weather reporting system or entity over the internet via a Wi-Fi connection to a Wi-Fi router located in or associated with the building 32.
  • the thermostat 26 is disposed inside of the building 32 and outside of the indoor unit 30 and is configured to measure an air temperature within a room or space to be cooled or heated by the system 10.
  • the thermostat 26 can be a single-stage thermostat, for example, that generates only one type of demand signal in response to a temperature within the room or spaced rising above (in the cooling mode) or falling below (in the heating mode) a setpoint temperature.
  • the control module 22 could be disposed in any suitable location, such as inside of or adjacent to the outdoor unit 28 or inside of or adjacent to the indoor unit 30, for example.
  • the outdoor heat exchanger 14 may operate as a condenser or as a gas cooler and may cool discharge-pressure working fluid received from the compressor 12 by transferring heat from the working fluid to air forced over the outdoor heat exchanger 14 by the outdoor blower 15, for example.
  • the outdoor blower 15 could include a fixed-speed, multi-speed or variable-speed fan.
  • the indoor heat exchanger 18 may operate as an evaporator in which the working fluid absorbs heat from air forced over the indoor heat exchanger 18 by the indoor blower 19 to cool a space within the home or building 32.
  • the indoor blower 19 could include a fixed-speed, multi-speed or variable-speed fan.
  • the outdoor heat exchanger 14 may operate as an evaporator, and the indoor heat exchanger 18 may operate as a condenser or as a gas cooler and may transfer heat from working fluid discharged from the compressor 12 to a space to be heated.
  • the algorithm 100 controls operation of the compressor 12 and switches the compressor 12 between the low-capacity and high-capacity modes.
  • the compressor 12 may be off.
  • the thermostat 26 may send a demand signal Y to the control module 22 in response to an air temperature in the space to be heated or cooled by the system 10 dropping below (in the heating mode) or rising above (in the cooling mode) a selected setpoint temperature.
  • the control module 22 initiates operation of the compressor 12 in the low-capacity mode (state 120). Initiating operation of the compressor 12 in the low-capacity mode may reduce or minimize an in-rush of energy and mechanical stress during start-up of the compressor 12.
  • the control module 22 may receive the outdoor ambient air temperature measured by the sensor 24 (input 130) and, when the system 10 is in the cooling mode, determine whether the outdoor ambient air temperature is above a first predetermined temperature value (such as 32 degrees Celsius (ninety degrees Fahrenheit), for example).
  • a first predetermined temperature value such as 32 degrees Celsius (ninety degrees Fahrenheit), for example.
  • the control module 22 may continue to operate the compressor in the low-capacity mode (state 120) until the cooling demand is satisfied (i.e., the temperature in the space to be cooled drops below the selected setpoint temperature as indicated by the thermostat 26 and the thermostat switches the demand signal Y to "off"), until the total runtime T of the compressor 12 since the receipt of the demand signal Y surpasses a predetermined low-capacity runtime T1, or until the compressor 12 or system 10 is manually shutdown or a diagnostic or protection algorithm overrides the algorithm 100.
  • the predetermined low-capacity runtime T1 could be approximately forty minutes, for example.
  • the control module 22 may shutdown the compressor 12 (state 140).
  • the first predetermined temperature value may be chosen to minimize runtime in the high-capacity mode in many or most houses or buildings in many or most weather conditions for one or more geographical locations.
  • the predetermined low-capacity runtime T1 may be chosen to avoid running the low-capacity mode longer than would be desirable for comfort and/or to prevent prematurely switching to the high-capacity mode (which would use more energy than would be desirable).
  • the compressor 12 could run in the low-capacity mode for a majority (e.g., 80% or more) of a cooling season (e.g., summer) for many or most houses or buildings in many or most climates or geographical regions.
  • a majority e.g., 80% or more
  • a cooling season e.g., summer
  • the control module 22 switches the compressor 12 from the low-capacity mode to the high-capacity mode (state 150).
  • the compressor 12 may continue to run in the high-capacity mode until the cooling demand is satisfied (or until the compressor 12 or system 10 is manually shutdown or a diagnostic or protection algorithm overrides the algorithm 100).
  • the control module 22 may shutdown the compressor 12 (state 140) instead of switching back to the low-capacity mode.
  • control module 22 may record the runtime T2 of the compressor 12 in the high-capacity mode and store the runtime T2 in a memory module (not shown) associated with the control module 22.
  • the control module 22 may wait (state 160) and allow the compressor 12 to continue operating in the low-capacity mode for a predetermined waiting period (e.g., about five seconds).
  • the predetermined waiting period may be chosen to ensure a stable start-up of the compressor 12 without significantly impacting overall system capacity and/or the system's ability to control comfort.
  • the control module 22 determines whether the last runtime T2 of the compressor 12 in the high-capacity mode was more than a predetermined time period (e.g., about five minutes)(state 170).
  • This predetermined time period may be chosen to determine whether the thermal load of the house or building 32 is high enough that a switch to the high-capacity mode is necessary or desirable to achieve desired comfort or low enough to continue operation in the low-capacity mode and still achieve desired comfort control. If the last high-capacity runtime T2 was greater than or equal to the predetermined time period, the control module 22 switches the compressor 12 from the low-capacity mode (state 120) to the high-capacity mode (state 150). Thereafter, the compressor 12 may continue to run in the high-capacity mode until the cooling demand is satisfied (or until the compressor 12 or system 10 is manually shutdown or a diagnostic or protection algorithm overrides the algorithm 100). When the cooling demand is satisfied, the control module 22 may shutdown the compressor 12 (state 140).
  • control module 22 may continue to operate the compressor 12 in the low-capacity mode (state 120) until the cooling demand is satisfied, until the total runtime T of the compressor 12 since the receipt of the demand signal Y surpasses the predetermined low-capacity runtime T1, or until the algorithm 100 is overridden.
  • the algorithm 100 may operate similarly or identically as described above, except the condition to be satisfied before the algorithm enters state 160 would be: whether the outdoor ambient air temperature is less than a second predetermined temperature value.
  • the second predetermined temperature value when the system 10 is in the heating mode may be different than the first predetermined temperature value in the cooling mode.
  • the second predetermined temperature value in the heating mode may be about 4.4 degrees Celsius (forty degrees Fahrenheit), for example.
  • the control module 22 may continue to operate the compressor 12 in the low-capacity mode (state 120) until heating demand is satisfied, until the runtime T surpasses the predetermined low-capacity runtime T1, or until the algorithm 100 is overridden. If, in the heating mode, the control module 22 determines that the outdoor ambient air temperature is less than the second predetermined temperature value, the algorithm 100 may enter state 160. From state 160, the algorithm 100 may operate similarly or identically as described above with respect to the cooling mode.
  • operation in the low-capacity mode in the heating mode may be sufficient to satisfy heating demand while outdoor-air temperatures are at or above 4.4 degrees Celsius (forty degrees Fahrenheit), and high-capacity mode operation may not be necessary or desirable until outdoor-air temperatures fall below 4.4 degrees Celsius (forty degrees Fahrenheit).
  • a third predetermined outdoor-air temperature e.g., -6.7 degree Celsius (twenty degrees Fahrenheit)
  • many heat-pump systems may not have sufficient capacity to satisfy heating demand even if continuously operating in the high-capacity mode. Therefore, alternative or supplemental heating systems may be employed instead of or in addition to such heat-pump systems.
  • the control module 22 may cause the compressor 12 to run in the high-capacity mode for a third predetermined runtime (e.g. thirty minutes) before turning on the alternative or supplemental heating systems.
  • variable-capacity compressor 12, control module 22 and algorithm 100 are capable of operating with a single-stage indoor thermostat 26 and an indoor unit 30 with a fixed-speed blower 19. Therefore, the control module 22 and algorithm 100 of the present invention allow a pre-existing climate control system having a fixed-capacity to be retrofitted to include the variable-capacity compressor 12 and control module 22 without also retrofitting the system to include a multi-stage thermostat and/or an indoor unit having a multi-speed blower.
  • Retrofitting a fixed-capacity climate control system to include the variable-capacity compressor 12 and control module 22 without also replacing the single-stage thermostat 26 and fixed-speed blower 19 improves the performance and efficiency of the climate-control system without the added significant expense and complexity associated with retrofitting the climate-control system to include a multi-stage thermostat and/or an indoor unit having a multi-speed blower.
  • a multi-stage thermostat could be employed, where the multi-stage thermostat is only connected to transmit a single demand signal (e.g., only one demand wire is connected to the compressor 12 and/or control module 22, as opposed to having both of a low-capacity demand wire and a high-capacity demand wire connected to the compressor 12 and/or control module 22).
  • first and second predetermined temperature values, the predetermined low-capacity runtime T1, the predetermined waiting period, and/or the predetermined time period described above may be chosen based on climate, geographical location, tonnage size of the compressor 12 relative to the thermal load of the house or building 32 and/or whether the system is operating in the cooling mode or the heating mode.
  • the outdoor-air temperature used in the algorithm 100 may not necessarily be an instantaneous or real-time temperature value. Instead, the control module 22 may acquire or determine an average outdoor-air temperature over previous operating cycles or over certain time periods to account for the effect of solar radiation and/or a thermal mass of the building 32 or the space to be heated or cooled.
  • control module 22 may be configured to record high-capacity-mode operating history versus outdoor-air temperature history and time of day. In such embodiments, the control module 22 may be configured to anticipate expected future days and times to switch to the high-capacity mode based on forecasted outdoor-air temperatures and the recorded operating history versus outdoor-air temperature history and time of day.
  • Figure 3 is a graph illustrating capacities of an exemplary variable-capacity compressor in the low and high-capacity modes at various outdoor-air temperatures and a thermal load of an exemplary house at various outdoor-air temperatures.
  • Figure 4 is a graph illustrating the percent runtime of the compressor in the low-capacity and high-capacity modes.
  • the control module 22 may operate the compressor only in the low-capacity mode.
  • the control module 22 may switch the compressor between the low-capacity and high-capacity modes to satisfy the demand.
  • the control module 22 may operate the compressor exclusively or nearly exclusively in the high-capacity mode.
  • the percent runtime shown in Figure 4 may be derived as the ratio of thermal load of the house over unit capacity for each capacity stage at a given outdoor ambient temperature shown in Figure 3 .
  • the predetermined runtime T1 (e.g., forty minutes) may be chosen to represent a maximum runtime in the low-capacity mode that is desirable or acceptable before it would be desirable to switch to the high-capacity mode.
  • the predetermined runtime T1 may vary depending on the relative capacities of the compressor in the low-capacity and high-capacity modes relative to the thermal load of the house.
  • Figure 3 is based on a sizing rule with the high-capacity mode being about 10 percent higher than the thermal load of the house at an ambient temperature of ninety-five degrees.
  • the predetermined ambient temperature where the high-capacity stage would start operating may be in the range of 29 to 32 degrees Celsius (eighty five to ninety degrees Fahrenheit).
  • the algorithm 200 may control operation of the compressor 12 and switch the compressor 12 between the low-capacity and high-capacity modes.
  • the compressor 12 may be off.
  • the thermostat 26 may send a demand signal Y to the control module 22 in response to an air temperature in the space to be heated or cooled by the system 10 dropping below (in the heating mode) or rising above (in the cooling mode) a selected setpoint temperature.
  • the control module 22 may initiate operation of the compressor 12 in the low-capacity mode (state 220). As described above, initiating operation of the compressor 12 in the low-capacity mode may reduce or minimize an in-rush of energy and mechanical stress during start-up of the compressor 12.
  • the control module 22 may (prior to, concurrently with or after initial startup of the compressor 12 at state 220) determine and set a low-capacity runtime threshold T1' and a high-capacity runtime threshold T2'.
  • the control module 22 may determine the runtime thresholds T1', T2' based on an outdoor ambient air temperature (input 232) and a comfort level selection (input 234).
  • the outdoor ambient air temperature may be received from the outdoor-air-temperature sensor 24.
  • the comfort level selection may be received from a comfort control interface 225 ( Figure 11 ) that is in communication with the control module 22.
  • the comfort control interface 225 may include a dial 227, for example, that is movable among a plurality of positions. In the particular configuration shown in Figure 11 , the dial 227 is movable among five different positions, each corresponding to a different one of comfort levels 1-5 (indicated by indicia 229 in Figure 11 ).
  • the comfort control interface 225 may be in communication with the control module 22 via a wired or wireless connection.
  • the comfort control interface 225 could be in communication with the control module 22 via an internet connection (wired or wireless), a cellular connection, Bluetooth® connection, radio-frequency signals, infrared signals and/or any other suitable means.
  • the user control interface 225 may include one or more buttons, switches, and/or touchscreen interfaces instead of or in addition to the dial 227.
  • the comfort control interface 225 could be, include or be a part of the thermostat 26, a computer, a smartphone, or a tablet, for example, or any other computing, control and/or communication device.
  • comfort level interface 225 allows a user to adjust the low-capacity and high-capacity runtime thresholds T1', T2' to adjust the energy-efficiency and performance of the system 10.
  • comfort level 1 is a setting that reduces the amount of time that the compressor 12 can run in the high-capacity mode and increases the amount of time that the compressor 12 can be operated in the low-capacity mode, thereby increasing the energy-efficiency of the system 10.
  • Comfort level 5 is a setting that increases the amount of time that the compressor 12 can run in the high-capacity mode and decreases the amount of time that the compressor 12 can run in the low-capacity mode, thereby increasing the performance of the system 10 (i.e., increasing the ability of the system 10 to more quickly cool or heat a space).
  • Figures 6 and 7 depict first and second lookup tables 231, 233 that provide exemplary low-capacity and high-capacity runtime thresholds T1', T2' for given outdoor ambient air temperatures (or ranges of temperatures) for each of five comfort levels.
  • the values of the lookup tables 231, 233 may be stored in a memory unit associated with the control module 22 and/or on a memory unit associated with any of a computer, a tablet, a smartphone, any handheld device, a cloud (i.e., an internet-connected server) and/or any suitable computing and/or memory device that can be configured to communicate with the control module 22.
  • the low-capacity runtime threshold T1' decreases as the comfort level increases from comfort level 1 to comfort level 5
  • the high-capacity runtime threshold T2' increases as the comfort level increases from comfort level 1 to 5.
  • the exemplary lookup tables 231, 233 shown in Figures 6 and 7 are used while the system 10 is operating in the cooling mode. Additional tables (not shown) may be stored in the memory unit of the control module 22 for use in a heating mode. Such additional tables may include different values than those provided in tables 231, 233.
  • the control module 22 may determine the low-capacity and high-capacity runtime thresholds T1', T2' for the outdoor ambient-air-temperature received at input 234 and the comfort level selection received at input 232 based on the tables 231, 233. Then, at states 236, 238, the control module 22 may set the thresholds T1', T2', respectively, to the values determined at state 230. It will be appreciated that the control module 22 could apply a formula or a series of calculations to determine the runtime thresholds T1', T2' rather than referencing lookup tables 231, 233.
  • the compressor 12 may continue to run in the low-capacity mode (state 220) as long as the demand signal Y is on and as long as a total runtime T of the compressor 12 since initial receipt of the demand signal Y is less than the low-capacity runtime threshold T1' that was set at state 236. If the demand signal Y is turned off, then the control module 22 may shut the compressor 12 off at state 240. If and when the total runtime T surpasses the low-capacity runtime threshold T1', the control module 22 may reset the total runtime T to zero (state 250) and switch the compressor 12 to the high-capacity mode (state 260).
  • the compressor 12 may continue to run in the high-capacity mode (state 260) as long as the demand signal Y is on and as long as a total runtime T is less than the high-capacity runtime threshold T2' that was set at state 238. If and when the total runtime T surpasses the high-capacity runtime threshold T2', the control module 22 may reset the total runtime T to zero (state 270) and the algorithm 200 may return to state 230 to determine and set the low-capacity and high-capacity runtime thresholds T1', T2' before returning the compressor 12 to the low-capacity mode at state 220. Thereafter, the algorithm 200 may repeat some or all of the steps described above until the demand signal Y is turned off or until operation of the compressor 12 is overridden (e.g., manually overridden or overridden by a compressor protection routine, for example).
  • Figures 8-10 depict runtimes of the compressor 12 in the low-capacity and high-capacity modes for various comfort levels.
  • Figure 8 depicts the low-capacity and high-capacity runtimes for a low comfort level (e.g., comfort level 1).
  • Figure 9 depicts the low-capacity and high-capacity runtimes for an intermediate comfort level (e.g., comfort level 3).
  • Figure 10 depicts the low-capacity and high-capacity runtimes for a high comfort level (e.g., comfort level 5).
  • higher comfort level settings allow the compressor 12 to run longer in the high-capacity mode, which improves the performance of the system 10.
  • the comfort level could be changed at any point during the algorithm 200 and the low-capacity and high-capacity runtime thresholds T1', T2' could be immediately updated in response to a change in the comfort level.
  • the control module 22 may adjust the runtime thresholds T1', T2' based on a weather forecast and/or current weather conditions such as humidity, cloud-cover and/or precipitation, for example. In some configurations, the control module 22 may increase the low-capacity runtime threshold T1' and/or decrease the high-capacity runtime threshold T2' for a given comfort level if current weather conditions include low humidity, significant cloud-cover and/or rain. In some configurations, the control module 22 may adjust the values of the tables 231, 233 (or utilize different tables in the algorithm 200) based on a climate of a particular geographical region in which the system 10 will be installed.
  • the comfort control interface 225 or the thermostat 26 could be configured to allow the user or installation contractor to input the geographical region or climate type in which the system 10 is installed.
  • the control module 22 may adjust the values of the tables 231, 233 based on historical data such as previous runtimes, previous outdoor-ambient-air temperatures and/or other previous weather conditions.
  • values of the tables 231, 233 could be adjusted based on current or predicted future energy costs.
  • a baseline set of values for the tables 231, 233 could be stored in the memory unit for future use.
  • the comfort level may be a parameter that is set by an installation contractor or by a service contractor at the time of installation of the system 10 or service of the system 10.
  • the comfort level selection may not be readily adjusted by a homeowner and/or occupants of the home or building.
  • an electrical utility company or entity may have the ability to set and adjust the comfort level selection and/or the ability to override a comfort level selection made by the homeowner and/or home/building occupant, for example.
  • the utility may select a comfort level that uses a lower amount of electricity during periods of high demand for electrical power in an area or community in which the home or building 32 is situated.
  • module may be replaced with the term circuit.
  • the term module may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; memory (shared, dedicated, or group) that stores code executed by a processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.
  • ASIC Application Specific Integrated Circuit
  • FPGA field programmable gate array

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Claims (9)

  1. Système de climatisation (10) comprenant une unité de compresseur à capacité variable (12) et un module de commande (22) commandant l'unité de compresseur (12), l'unité de compresseur (12) fonctionnant dans un premier mode de capacité et dans un second mode de capacité qui est supérieur au premier mode de capacité, le module de commande (22) étant configuré pour commuter l'unité de compresseur (12) entre un état d'arrêt, le premier mode de capacité et le second mode de capacité sur la base d'un signal de demande (Y) et de données de température de l'air extérieur,
    dans lequel le module de commande (22) est configuré pour commuter l'unité de compresseur (12) de l'état d'arrêt au premier mode de capacité en réponse à la réception du signal de demande (Y), et
    dans lequel le module de commande (22) est configuré pour commuter l'unité de compresseur (12) du premier mode de capacité au second mode de capacité sur la base du fait que l'unité de compresseur a fonctionné dans le premier mode de capacité pendant plus d'une première période de temps prédéterminée (T1, T1'), et dans lequel le module de commande (22) est configuré pour commuter l'unité de compresseur (12) du premier mode de capacité au second mode de capacité tout en recevant le même signal de demande (Y),
    caractérisé en ce que :
    le module de commande est configuré pour commuter l'unité de compresseur du premier mode de capacité au second mode de capacité si la valeur de température mesurée des données de température de l'air extérieur est supérieure à une valeur de température prédéterminée et un temps d'exécution précédent (T2, T2') de l'unité de compresseur (12) dans le second mode de capacité pendant une période de demande précédente dépasse une seconde période de temps prédéterminée.
  2. Système de climatisation selon la revendication 1, dans lequel le module de commande est configuré pour faire fonctionner l'unité de compresseur (12) dans le premier mode de capacité si une valeur de température mesurée des données de température de l'air extérieur est inférieure à une valeur de température prédéterminée, et dans lequel le module de commande (22) fait fonctionner l'unité de compresseur (12) dans le premier mode de capacité jusqu'à ce qu'un temps d'exécution total (T) de l'unité de compresseur (12) depuis la réception du signal de demande (Y) dépasse la première période de temps prédéterminée (T1, T1') ou le signal de demande s'éteint.
  3. Système de climatisation (10) selon la revendication 1, dans lequel le module de commande (22) est configuré pour recevoir le signal de demande à partir d'un thermostat à étage unique (26) disposé dans un espace à refroidir (32) par le système de climatisation (10).
  4. Système de climatisation (10) selon la revendication 3, comprenant en outre un échangeur de chaleur intérieur (18) recevant le fluide de travail à partir de l'unité de compresseur (12) et un ventilateur (19) forçant l'air dans une relation de transfert de chaleur par convection avec le fluide de travail dans l'échangeur de chaleur intérieur (18), le ventilateur (19) comprenant un moteur à vitesse fixe ou un moteur à vitesse variable pouvant fonctionner à une prise à vitesse fixe sélectionnable.
  5. Système de climatisation (10) selon la revendication 1, dans lequel le module de commande (22) est configuré pour commuter l'unité de compresseur (12) du premier mode de capacité aux seconds modes de capacité en fonction de si le temps d'exécution précédent (T2) était supérieure à cinq minutes.
  6. Système de climatisation (10) selon la revendication 1, comprenant en outre une interface de commande de confort (225) configurée pour être positionnée à l'un d'une pluralité de réglages de niveau de confort, dans lequel un premier des réglages de niveau de confort correspond à un mode de fonctionnement écoénergétique et un second des réglages de niveau de confort correspondent à un mode de fonctionnement à hautes performances,
    dans lequel, pour une température d'air extérieur donnée, le module de commande est configuré pour faire fonctionner l'unité de compresseur dans le premier mode de capacité pendant une période plus longue de temps dans le mode de fonctionnement écoénergétique que dans le mode de fonctionnement à haute performance avant le passage au second mode de capacité.
  7. Système de climatisation (10) selon la revendication 6, dans lequel le seuil de temps d'exécution de faible capacité (T1') et le seuil de temps d'exécution de haute capacité (T2') sont déterminés sur la base de l'un sélectionné des réglages de niveau de confort.
  8. Procédé de commande d'un compresseur (12) pouvant fonctionner dans un premier mode de capacité et dans un second mode de capacité qui est supérieur au premier mode de capacité, le procédé comprenant :
    la réception d'un signal de demande (Y) ;
    la comparaison d'une température de l'air extérieur à une valeur de température prédéterminée ;
    le fonctionnement du compresseur (12) en réponse à la réception du signal de demande (Y) dans l'un des premier et second modes de capacité sur la base de la comparaison de la température de l'air extérieur et de la valeur de température prédéterminée,
    dans lequel le compresseur (12) est commuté d'un état d'arrêt au premier mode de capacité en réponse à la réception du signal de demande (Y),
    dans lequel le compresseur (12) est commuté du premier mode de capacité au second mode de capacité tout en recevant le même signal de demande (Y), et
    dans lequel le compresseur est commuté du premier mode de capacité au second mode de capacité en fonction du fait que le compresseur a fonctionné dans le premier mode de capacité pendant plus d'une première période de temps prédéterminée (T1, T1'),
    caractérisé en ce que :
    le compresseur est commuté du premier mode de capacité au second mode de capacité si la valeur de température mesurée de la température de l'air extérieur est supérieure à la valeur de température prédéterminée et un temps d'exécution précédent (T2, T2') de l'unité de compresseur dans le second mode de capacité pendant une période de demande précédente dépasse une seconde période de temps prédéterminée.
  9. Procédé selon la revendication 8, comprenant en outre le fonctionnement du compresseur (12) uniquement dans le premier mode de capacité jusqu'à ce que la demande soit satisfaite si la température de l'air extérieur est inférieure à la valeur de température prédéterminée et si un temps d'exécution total (T) du compresseur (12) depuis la réception du signal de demande (Y) est inférieure à la première période de temps prédéterminée (T1, T1').
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KR101922958B1 (ko) 2018-11-28
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KR20160138571A (ko) 2016-12-05
EP3126676A1 (fr) 2017-02-08
CN109028496B (zh) 2020-12-08
CN109028496A (zh) 2018-12-18
CN106133318A (zh) 2016-11-16
CN106133318B (zh) 2018-06-29
EP3800354A1 (fr) 2021-04-07
EP3800354B1 (fr) 2023-07-05
EP3126676A4 (fr) 2017-11-22

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