US20100064703A1 - Standby variable frequency compressor drive - Google Patents

Standby variable frequency compressor drive Download PDF

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Publication number
US20100064703A1
US20100064703A1 US12/521,454 US52145409A US2010064703A1 US 20100064703 A1 US20100064703 A1 US 20100064703A1 US 52145409 A US52145409 A US 52145409A US 2010064703 A1 US2010064703 A1 US 2010064703A1
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United States
Prior art keywords
compressor
voltage
variable
set forth
frequency
Prior art date
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Abandoned
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US12/521,454
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English (en)
Inventor
Raymond L. Senf, Jr.
Harold P. Hill, JR.
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.)
Carrier Corp
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Carrier Corp
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Filing date
Publication date
Application filed by Carrier Corp filed Critical Carrier Corp
Assigned to CARRIER CORPORATION reassignment CARRIER CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HILL, HAROLD P., JR., SENF, RAYMOND L., JR.
Publication of US20100064703A1 publication Critical patent/US20100064703A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • F25B49/025—Motor control arrangements
    • 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
    • F25B2400/00—General features or devices for refrigeration machines, plants or systems, combined heating and refrigeration systems or heat-pump systems, i.e. not limited to a particular subgroup of F25B
    • F25B2400/13—Economisers
    • 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
    • F25B2600/021—Inverters therefor
    • 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
    • F25B2600/026—Compressor control by controlling unloaders
    • F25B2600/0261—Compressor control by controlling unloaders external to the compressor
    • 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
    • F25B2600/11—Fan speed control
    • F25B2600/111—Fan speed control of condenser fans
    • 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
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D29/00—Arrangement or mounting of control or safety devices
    • F25D29/003—Arrangement or mounting of control or safety devices for movable devices
    • 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

Definitions

  • This invention relates generally to refrigeration systems and, more particularly, to selected use of a variable speed drive for the compressor during unloaded modes of operation.
  • Transport refrigeration systems include a cargo space to be cooled and a refrigeration system for providing the heat exchange capabilities for maintaining the controlled temperature range within the cargo space.
  • a temperature sensor and a control are operatively connected to the cooling circuit in order to modulate the output thereof in order to maintain the desired temperature levels.
  • the cooling circuit is designed for a capacity that is sufficient for accommodating maximum heat losses into and through the transportable cooling unit, with the losses being directly proportioned to the outside ambient temperature.
  • the controller adjusts the cooling circuit by turning the cooling circuit on and off in response to the sensed temperature in the cargo space. That is, the cooling circuit is turned off when the sensed temperature reaches a lower set point and is turned on when the sensed temperature reaches a predetermined upper set point.
  • the cooling circuit has more capacity than is needed and the deficiency of the system is substantially reduced during such chilled conditions. That is, in such chilled conditions, although the cooling circuit has too much capacity, it needs to run continuously in order to maintain temperature control on a transport volume.
  • the on/off mode of operation for frozen conditions comprises an estimated 60% of the market demand, whereas the chilled part-load conditions comprises about 40% of the market demand.
  • the on/off mode of operation for frozen conditions comprises an estimated 60% of the market demand, whereas the chilled part-load conditions comprises about 40% of the market demand.
  • compressor power is reduced by conventional methods to a range where variable speed can be effectively and efficiently used by way of a relatively small inverter.
  • an inverter is provided such that at times when operating under part load conditions, the inverter is selectively applied to provide variable voltage and frequency to the compressor drive motor so that it can be run at selectively variable speeds on a continuous basis thereby achieving high operating efficiencies.
  • an evaporator flow control apparatus is also applied if the system capacity remains higher than the load requirements.
  • the system will operate with line voltage and frequency until the temperature demand is stable, at which point the power source will be switched from line voltage and frequency to a variable voltage and frequency.
  • FIG. 1 is a schematic illustration of a vapor compression system in accordance with the prior art.
  • FIG. 2 is a schematic illustration of a revised version thereof in accordance with the present invention.
  • FIG. 3 is a graphic illustration of the sequence of modal operation in accordance with the present invention.
  • FIG. 1 shows a vapor compression system 10 in accordance with the prior art.
  • Vapor compression system 10 includes a main vapor compression circuit including a compressor 12 , a condenser 14 , an expansion device 16 and an evaporator 18 . These components are serially connected by main refrigerant lines to provide refrigerant flow from discharge port 13 of compressor 12 through line 20 to condenser 14 , from condenser 14 through line 22 to expansion device 16 , from expansion device 16 through line 24 to evaporator 18 , and from evaporator 18 through line 26 back to a suction port 15 of compressor 12 .
  • An economizer circuit is also provided and is connected between condenser 14 and at least one of an intermediate pressure port 28 and suction port 15 of compressor 12 .
  • This circuit is preferably provided in the form of an economizer refrigerant line 40 leading from condenser 14 to an auxiliary expansion device 42 , and from expansion device 42 through economizer refrigerant line 44 to heat exchanger 32 .
  • the economizer circuit extends from heat exchanger 32 through line 38 to an intermediate pressure port 28 of compressor 12 .
  • An economizer shutoff valve 46 can advantageously be positioned along economizer refrigerant lines, for example along line 40 , for selectively allowing and blocking flow through the economizer circuit as well. Alternatively, if expansion device 42 is an electronic expansion device, then valve 40 is not needed.
  • system 10 also includes a bypass circuit which is connected between an intermediate pressure port 28 of compressor 12 and suction port 15 of compressor 12 .
  • the bypass circuit allows for unloaded operation of compressor 12 .
  • the bypass circuit is adapted to flow through economizer heat exchanger 32 so as to sub-cool the main refrigerant flow with flow from the bypass circuit, thus utilizing economizer heat exchanger 32 , and improving efficiency, during unloaded operation.
  • bypass refrigerant line 38 advantageously leads to economizer heat exchanger 32 , and from heat exchanger 32 through line 36 and back to suction portion 15 of compressor 12 .
  • a bypass shutoff valve 34 is advantageously positioned along bypass line 36 leading from heat exchanger 32 to suction port 15 , for selectively allowing and blocking flow through the bypass circuit.
  • Main refrigerant line 22 flows through economizer heat exchanger 32 so as to be exposed to heat transfer relationship with flow in line 38 in heat exchanger 32 .
  • heat exchanger 32 is adapted to receive a first flow from main refrigerant line 22 and a second flow from at least one of the economizer circuit and the bypass circuit, and heat transfer occurs in both full-load economized operation, and advantageously in part-load operation as well.
  • valve 34 when compressor 12 is to be operated in an unloaded state, valve 34 is open to pass a portion of the refrigerant through intermediate pressure port 28 , representing a portion of refrigerant flowing through compressor 12 which is compressed to an intermediate pressure, thereby unloading compressor 12 .
  • main refrigerant flow is sub-cooled in economizer heat exchanger 32 to provide performance enhancement of the system in this mode of operation.
  • intermediate pressure port 28 depending upon location of intermediate pressure port 28 , the intermediate pressure of flow exiting this port is relatively close to suction pressure, thereby increasing available temperature difference for heat transfer interaction in economizer heat exchanger 32 .
  • a control member 48 may advantageously be provided and operatively associated with shutoff valves 34 , 46 , or expansion device 42 if electronically controlled, for selectively positioning either of these valves in the closed or open position so as to allow for operation of system 10 as desired, in the full load economized mode or in the unloaded mode, with heat exchanger 32 still active and functional to enhance system performance.
  • system 10 can also operate in a full load non-economized mode with both valves 34 , 46 closed.
  • an evaporator flow control apparatus 49 may be brought into use as the load on the system decreases.
  • the evaporator flow control apparatus 49 maybe f various types such as a suction modulation valve or a pulse width modulation valve, the purpose of which is to decrease flow of refrigerant to the compressor and in doing so balancing the compressor capacity with the load to prevent operation with low coil temperatures.
  • the evaporator flow control apparatus may also be a PWM (pulse width modulated) compressor which is a scroll type compressor with an integral unloading system that utilizes a pulse width modulated demand signal to engage and disengage the intermeshing scroll wraps.
  • PWM pulse width modulated
  • Compressor unloading is accomplished via separation/lifting of the non-orbiting scroll set from the orbiting scroll set. This separation is controlled via a fluid bypass PWM solenoid valve. Capacity modulation is ultimately controlled by pulsing this solenoid valve switching the compressor from high capacity to low capacity operation.
  • the compressor 12 of the FIG. 1 embodiment is replaced with a compressor 51 which is capable of selectively operating at either a fixed speed mode of operation or at a variable speed mode of operation.
  • the compressor 51 may be a reciprocating compressor, but it could also be of another type, such as a scroll compressor or a rotary compressor.
  • the compressor 51 is electrically connected directly to the control 52 by a plurality of power connecters 53 .
  • the compressor 51 is also electrically connected by a plurality of power connectors 54 to an inverter 56 , which in turn is connected to the control 52 by the connectors 57 .
  • Control of the inverter 56 is brought about by the control 52 through the connector 58 .
  • Line power is fed to the control 52 by way of the lines 59 .
  • the compressor 51 can be selectively operated by operation of the contactors 61 and 62 to provide either line voltage and frequency to the compressor 51 or variable voltage and frequency. That is, with the contactors 61 closed and the contactors 62 open, line voltage will be provided to the compressor by way of connectors 53 . Alternatively, with the contactors 62 closed and contactors 61 open, line voltage and frequency will be provided to the inverter 56 , and the inverter 56 will then provide variable voltage and frequency to the compressor 51 by way of connectors 54 .
  • the modulation valve 49 is provided in the same manner as the FIG. 1 embodiment, but the bypass circuit shown in the FIG. 1 embodiment has been removed.
  • the present invention will be described in terms of use with a modulation valve and with no bypass circuit. However, it should be understood that the present invention could be equally useful in systems wherein a bypass circuit is provided.
  • FIG. 3 there is shown a typical illustration of the variation of both cargo temperature and supply temperature as they vary with time as the system operation tends toward operating in an unloaded condition. As will be seen, with the passing of time, the cargo temperature is gradually brought down to a temperature that is closer to the supply temperature and will eventually reach the set point.
  • FIG. 3 there is shown a sequence of various modes of operation when operating at part load and unloaded conditions. These modes of operation correspond to the temperature conditions directly above. That is, for part load conditions, wherein the difference between the cargo temperature and the supply temperature is substantially constant, the compressor 51 is operated in an economized mode using line voltage and frequency. This is shown by the line F-E.
  • the compressor is switched out of the economized mode and into a standard mode of operating using line voltage and frequency. This mode is used when the load is being pulled down to the perishable range. This mode operation is shown at E-D in FIG. 3 .
  • mode 2 operation which is used for start up on frozen and when a chilled load is being pulled down to the perishable range, the compressor is operated in the unloaded mode using line voltage and use of the evaporator flow control apparatus 49 as described hereinabove.
  • the drive can be sized much smaller when used only in mode 1 because the thermodynamics of a vapor compression, closed cooling system provides a fairly linear reduction in system compression power due to inherent suction gas density changes with substantially lower box temperatures in the perishable range.
  • the reduction in suction gas density and mass flow after pull down allows for significantly smaller variable speed drive when near set point.
  • the mode 1 operation is used for perishable products when the system has more capacity than is needed. Perishable products require tight temperature control which is best achieved when the system can operate continuously.
  • the system will run using line voltage and frequency in the unloaded compressor mode of operation and then the evaporator flow control apparatus 49 will engage until the temperature demand is stable.
  • the controller 52 will decided to switch the contactors 61 and 62 to turn off the line voltage and frequency and switch to a variable voltage and frequency to operate the compressor 51 on a variable speed basis.
  • the controller 52 will precisely control the compressor speed to provide the correct temperature of the transport load for all perishable conditions.
  • the variable speed will run to a minimum optimized speed and will then operate the evaporator flow control apparatus 49 if the system capacity remains higher than the transport load requirement until steady temperature control is obtained.
  • the system will switch the contactors 61 and 62 to resume fixed speed operation with line voltage and frequency.
  • variable speed drive is not used on the compressor at high capacity conditions, it may be advantageous to switch the variable speed drive to the condenser fan motor to increase fan speed for added condenser fan performance where the condenser capacity is limited. This would provide a cost advantage by keeping the condenser size at its minimum but allowing the system to be more effective at high temperature pull down conditions, increase compressor reliability by reducing discharge temperature and pressure, and utilize a critical component not being used.
  • variable speed drive in mode 1 only because it provides a redundant system. That is, if for some reason the drive failed during transportation, the system can successfully operate without the variable speed drive and there would be no loss of load by using current control strategy. In addition, drive reliability will be better because it will operate in lightly loaded conditions.
  • variable speed drive can be used to heat the compressor motor by applying a small DC voltage to the compressor for arctic applications where crankcase heaters are applied and purchased separately.
  • the variable speed drive can replace the heaters and can be offered as a standard package to all customers reducing cost and reliability. With this, the invention will allow the cooling system to have the ability to work in all regions of the world without special modifications or options.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Air Conditioning Control Device (AREA)
  • Devices That Are Associated With Refrigeration Equipment (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
US12/521,454 2006-12-29 2006-12-29 Standby variable frequency compressor drive Abandoned US20100064703A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2006/049618 WO2008082396A1 (en) 2006-12-29 2006-12-29 Standby variable frequency compressor drive

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US (1) US20100064703A1 (xx)
EP (1) EP2126477A4 (xx)
JP (1) JP2010515007A (xx)
CN (1) CN101578489B (xx)
BR (1) BRPI0622229A2 (xx)
HK (1) HK1138350A1 (xx)
WO (1) WO2008082396A1 (xx)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150013361A1 (en) * 2012-03-09 2015-01-15 Carrier Corporation Closed Loop Capacity And Power Management Scheme For Multi Stage Transport Refrigeration System
US20160311294A1 (en) * 2015-04-27 2016-10-27 Carrier Corporation Regulated output power from a transport refrigeration unit
US9868336B2 (en) 2014-09-26 2018-01-16 Thermo King Corporation Method and system for controlling condenser/radiator airflow
US10203141B1 (en) * 2016-10-25 2019-02-12 Regal Beloit America, Inc. Multi-stage compressor with variable speed drive and method of use
US10352594B2 (en) * 2017-05-11 2019-07-16 Haier Us Appliance Solutions, Inc. Sealed heat exchange system and air conditioner
US10422563B2 (en) * 2015-05-11 2019-09-24 Lg Electronics Inc. Refrigerator and control method thereof
WO2020167666A1 (en) * 2019-02-11 2020-08-20 Regal Beloit America, Inc. Multi-capacity compressor with variable speed drive and method of use
US11955915B2 (en) 2020-12-14 2024-04-09 Danfoss (Tianjin) Ltd. Variable-frequency compressor with adaptive heating power control and method for operating the same

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WO2013020034A2 (en) * 2011-08-03 2013-02-07 Johnson Controls Technology Company Variable frequency generator power supply for centrifugal chillers
US11387762B1 (en) 2021-03-15 2022-07-12 Regal Beloit America, Inc. Controller and drive circuits for electric motors

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US5107685A (en) * 1989-12-05 1992-04-28 Kabushiki Kaisha Toshiba Air conditioning system having a control unit for fine adjustment of inverter input current
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US6659726B2 (en) * 2001-12-31 2003-12-09 Carrier Corporation Variable speed control of multiple motors
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US6725680B1 (en) * 2002-03-22 2004-04-27 Whirlpool Corporation Multi-compartment refrigerator control algorithm for variable speed evaporator fan motor
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US6820434B1 (en) * 2003-07-14 2004-11-23 Carrier Corporation Refrigerant compression system with selective subcooling
US20060250105A1 (en) * 2005-05-06 2006-11-09 York International Corporation Variable speed drive for a chiller system with a switched reluctance motor

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150013361A1 (en) * 2012-03-09 2015-01-15 Carrier Corporation Closed Loop Capacity And Power Management Scheme For Multi Stage Transport Refrigeration System
US9908452B2 (en) * 2012-03-09 2018-03-06 Carrier Corporation Closed loop capacity and power management scheme for multi stage transport refrigeration system
US9868336B2 (en) 2014-09-26 2018-01-16 Thermo King Corporation Method and system for controlling condenser/radiator airflow
US20160311294A1 (en) * 2015-04-27 2016-10-27 Carrier Corporation Regulated output power from a transport refrigeration unit
US10422563B2 (en) * 2015-05-11 2019-09-24 Lg Electronics Inc. Refrigerator and control method thereof
US10203141B1 (en) * 2016-10-25 2019-02-12 Regal Beloit America, Inc. Multi-stage compressor with variable speed drive and method of use
US10352594B2 (en) * 2017-05-11 2019-07-16 Haier Us Appliance Solutions, Inc. Sealed heat exchange system and air conditioner
WO2020167666A1 (en) * 2019-02-11 2020-08-20 Regal Beloit America, Inc. Multi-capacity compressor with variable speed drive and method of use
US11955915B2 (en) 2020-12-14 2024-04-09 Danfoss (Tianjin) Ltd. Variable-frequency compressor with adaptive heating power control and method for operating the same

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EP2126477A1 (en) 2009-12-02
EP2126477A4 (en) 2012-07-11
CN101578489A (zh) 2009-11-11
WO2008082396A1 (en) 2008-07-10
BRPI0622229A2 (pt) 2012-01-03
HK1138350A1 (en) 2010-08-20
CN101578489B (zh) 2012-03-14
JP2010515007A (ja) 2010-05-06

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