US20150260448A1 - Internal control systems of evaporator and condenser fan motor assemblies of a refrigeration system in a refrigerator unit - Google Patents

Internal control systems of evaporator and condenser fan motor assemblies of a refrigeration system in a refrigerator unit Download PDF

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US20150260448A1
US20150260448A1 US14/656,241 US201514656241A US2015260448A1 US 20150260448 A1 US20150260448 A1 US 20150260448A1 US 201514656241 A US201514656241 A US 201514656241A US 2015260448 A1 US2015260448 A1 US 2015260448A1
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Prior art keywords
fan motor
compressor
state
internal control
evaporator
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US14/656,241
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English (en)
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Ramiro AVILA
Michael Devine
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True Manufacturing Co Inc
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True Manufacturing Co Inc
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Priority to US14/656,241 priority Critical patent/US20150260448A1/en
Assigned to TRUE MANUFACTURING COMPANY, INC. reassignment TRUE MANUFACTURING COMPANY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AVILA, RAMIRO, DEVINE, MICHAEL
Publication of US20150260448A1 publication Critical patent/US20150260448A1/en
Abandoned legal-status Critical Current

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    • 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
    • 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
    • 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
    • F25D17/00—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces
    • F25D17/04—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection
    • F25D17/06—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection by forced circulation
    • F25D17/062—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection by forced circulation in household refrigerators
    • 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
    • F25D17/00—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces
    • F25D17/04—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection
    • F25D17/06—Arrangements for circulating cooling fluids; Arrangements for circulating gas, e.g. air, within refrigerated spaces for circulating air, e.g. by convection by forced circulation
    • F25D17/067—Evaporator fan 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
    • F25B2600/02—Compressor control
    • F25B2600/025—Compressor control by controlling speed
    • F25B2600/0251—Compressor control by controlling speed with on-off operation
    • 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
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2600/00—Control issues
    • F25B2600/11—Fan speed control
    • F25B2600/112—Fan speed control of evaporator 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
    • F25D2323/00—General constructional features not provided for in other groups of this subclass
    • F25D2323/002—Details for cooling refrigerating machinery
    • F25D2323/0028—Details for cooling refrigerating machinery characterised by the fans
    • F25D2323/00283—Details for cooling refrigerating machinery characterised by the fans the fans allowing rotation in reverse direction
    • 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
    • F25D2600/00—Control issues
    • F25D2600/02—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
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2700/00—Means for sensing or measuring; Sensors 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
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2700/00—Means for sensing or measuring; Sensors therefor
    • F25D2700/12—Sensors measuring the inside temperature
    • 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 refrigerator units and, more particularly, to refrigerator units that comprise a refrigeration system with an evaporator fan motor assembly having an internal control system and/or a condenser fan motor assembly having an internal control system wherein the evaporator fan motor and/or the condenser fan motor can be operated intermittently for assisting in reducing energy consumption.
  • the principal components of a typical refrigerator unit include a storage compartment which is refrigerated by a refrigeration system and is used to store and/or display various food products at low temperatures.
  • the refrigeration systems of typical refrigerator units include a refrigerant flowing serially through a compressor, a condenser, a thermal expansion valve or capillary tube, and an evaporator. Additionally a condenser fan motor assembly is used to blow air across the coils of the condenser. An evaporator (cold air) fan motor assembly is used to blow air across the evaporator.
  • the condenser fan motor runs while the compressor operates (i.e., the compressor ON state). The compressor typically cycles on and off about three times an hour. Additionally, the evaporator fan motor runs both during the compressor ON state and during the compressor OFF state.
  • the constant running of the evaporator fan motor assists in providing uniform product temperature throughout the interior volume of the storage compartment regardless of the relationship of the ON-OFF state of the compressor ((whether the compressor cycles from the ON state to the OFF state frequently (e.g., more than 6 cycles per hour) or infrequently (e.g., once or twice an hour)).
  • the evaporator fan motor can be powered off when the compressor is powered off. This is typically done for energy saving reasons. If the actual compressor run time (i.e., the ratio of on time to real time) is very low because of low ambient temperature or general sizing of the refrigeration system to the volume of the storage compartment, this can lead to instability of the product temperature inside the storage compartment.
  • the product temperature may begin to swing up and down with the compressor cycles, thereby adversely affecting the integrity of the food products stored within the storage compartment. Accordingly, turning off the evaporator fan motor during the compressor OFF state can save energy, but can have a negative effect on the food product.
  • the condenser fan motor runs while the compressor operates (i.e., the compressor ON state) and the evaporator fan motor runs both during the compressor ON state and during the compressor OFF state.
  • the constant running of the evaporator fan motor assists in providing uniform product temperature throughout the interior volume of the storage compartment, however the constant running of the evaporator fan motor also increases the energy consumption of the refrigerator unit.
  • an external control system may be employed which may be adapted to control the compressor, condenser fan and/or evaporator fan motor.
  • the control system may be connected to an electronic thermostat and can control each of the refrigeration components based on the temperature sensed by the electronic thermostat.
  • This external control system may be disposed on or in the refrigerator unit.
  • Such an external control system, including the electronic thermostat may be expensive to design and implement. Additionally, the external control system may need to be tailored to various types and/or sizes of refrigerator units.
  • one embodiment of the invention is directed to a refrigeration system in which the condenser fan motor and/or the evaporator fan motor may be operated by control systems internal to each of the condenser fan motor assembly and/or the evaporator fan motor assembly for reduced energy consumption while maintaining uniform product temperature in the storage compartment.
  • Another embodiment of the invention is directed to a refrigeration system for use in a refrigerator unit, the refrigeration system comprising a compressor having an ON state and an OFF state, a condenser, a thermostat, an evaporator, and an evaporator fan motor assembly comprising an evaporator fan motor, a fan blade, and an internal control system, wherein the internal control system is adapted to sense the compressor state and is further adapted to operate the evaporator fan motor in response to the sensed compressor state.
  • Another embodiment of the invention is directed to a method of operating a refrigeration system for use in a refrigerator unit, wherein the refrigeration system comprises a compressor having an ON state and an OFF state, a condenser, a thermostat, an evaporator, and an evaporator fan motor assembly comprising an evaporator fan motor, a fan blade, and an internal control system, wherein the internal control system is adapted to repeatedly cycle the evaporator fan motor between an ON state and an OFF state when the compressor is in the OFF state.
  • the method comprises the steps of: turning the compressor to the ON state; sensing by the internal control system of the evaporator fan motor assembly that the compressor is in the ON state and turning the evaporator fan motor to the ON state; turning the compressor to the OFF state; sensing by the internal control system of the evaporator fan motor assembly that the compressor is in the OFF state and repeatedly cycling the evaporator fan motor between the ON state and the OFF state.
  • FIG. 1 is a right perspective view of a refrigerator unit according to an embodiment of the invention.
  • FIG. 2 is a schematic drawing of a refrigeration system of a refrigerator unit according to an embodiment of the invention
  • FIG. 3 is a wiring diagram of components of a refrigeration system of a refrigerator unit according to an embodiment of the invention.
  • FIG. 4 is a flowchart of a method of operation of a refrigeration system of refrigerator unit having an evaporator fan motor assembly with an internal control system according to an embodiment of the invention
  • FIG. 5 is a flowchart of a method of operation of a refrigeration system of a refrigerator unit having a condenser fan motor assembly with an internal control system according to an embodiment of the invention
  • FIG. 6 is a flowchart of a method of operation of a refrigeration system of a refrigerator unit having an evaporator fan motor assembly with an internal control system and a condenser fan motor assembly with an internal control system according to an embodiment of the invention
  • FIG. 7 is a time plot of a method of operation of a refrigeration system of a refrigerator unit having an evaporator fan motor assembly with an internal control system and a condenser fan motor assembly with an internal control system according to an embodiment of the invention.
  • FIG. 7A is a time plot of a method of operation of a refrigeration system of a refrigerator unit having an evaporator fan motor assembly with an internal control system and a condenser fan motor assembly with an internal control system according to an embodiment of the invention.
  • refrigerator unit 10 having a refrigeration system disposed within refrigerator unit 10 .
  • refrigerator unit 10 may be a glass door merchandiser which may be used to store and display products such as food and/or drinks for sale.
  • refrigerator unit 10 may be any type of refrigeration unit, including, but not limited to, residential, commercial and/or industrial refrigerators, vending machines, and freezers.
  • Refrigerator unit 10 may include a lower portion providing a refrigeration system housing 12 and an upper portion providing a cabinet 14 . Some or all of components of refrigeration system 110 (see FIG. 2 ) may be disposed within refrigeration system housing 12 .
  • cabinet 14 includes a top 16 , a bottom 18 , opposed sides 20 and a back 22 defining a storage compartment 24 having an opening 26 .
  • Opening 26 in the embodiment shown, may be closed by a pair of doors 28 which may be substantially identical, each door 28 being attached to one of said cabinet sides 20 in swinging relation to said opening 26 . While certain embodiments include a pair of doors 28 , it will be understood by one of ordinary skill in the art that any number of doors may be used without departing from the scope of the invention.
  • FIG. 2 illustrates certain principal components of one embodiment of a refrigeration system 110 for use in a refrigerator unit 10 .
  • Refrigeration system 110 may include a compressor 112 , a condenser 114 for condensing compressed refrigerant vapor discharged from the compressor 112 , a thermal expansion device 118 for lowering the temperature and pressure of the refrigerant, an evaporator 120 , and a thermostat or temperature control 130 .
  • Thermostat 130 may be adapted to control the operation of refrigeration system 110 in response to the temperatures measured within storage compartment 24 .
  • compressor 112 may have an ON state (“ON”) and an OFF state (“OFF”) wherein thermostat 130 causes compressor 112 to turn ON or OFF based on the temperature within storage compartment 24 .
  • Thermostat 130 may be a mechanical or electrical thermostat or temperature control.
  • thermostat 130 may include a relay and capillary tube for measuring the temperature within storage compartment 24 and for controlling compressor 112 .
  • the thermal expansion device 118 may include, but is not limited to, a capillary tube, a thermostatic expansion valve or an electronic expansion valve.
  • refrigeration system 110 may also include a temperature sensing bulb (not shown) placed at the outlet of the evaporator 120 to control thermal expansion device 118 .
  • a form of refrigerant cycles through these components via a lines 128 a , 128 b , 128 c.
  • Refrigeration system 110 may further include a condenser fan motor assembly 115 which may be positioned to blow a gaseous cooling medium (e.g., air) across condenser 114 .
  • Condenser fan motor assembly 115 may include a fan motor 115 a , fan blade(s) 115 b and an internal control system (not shown) adapted to control the operation of condenser fan motor 115 a .
  • Condenser fan motor 115 a may be connected to fan blade(s) 115 b in any manner known in the art to cause fan blade(s) 115 b to rotate and thus move air.
  • the internal control system of condenser fan motor assembly 115 may be adapted to sense the ON or OFF state of compressor 112 and may be further adapted to operate condenser fan motor 115 a in response to the sensed compressor 112 state (e.g., the ON state or the OFF state).
  • refrigeration system 110 may further include an evaporator fan motor assembly 127 which may be positioned to blow air across evaporator 120 in order to circulate cooled air within refrigerator unit 10 .
  • Evaporator fan motor assembly 127 may include a fan motor 127 a , fan blade(s) 127 b and an internal control system (not shown) adapted to control the operation of evaporator fan motor 127 a .
  • Evaporator fan motor 127 a may be connected to fan blade(s) 127 b in any manner known in the art to cause fan blade(s) 127 b to rotate and thus move air.
  • the internal control system of evaporator fan motor assembly 127 may be adapted to sense the ON or OFF state of compressor 112 and may be further adapted to operate evaporator fan motor 127 a in response to the sensed compressor 112 state (e.g., the ON state or the OFF state).
  • the internal control systems in each of evaporator fan motor assembly 127 and condenser fan motor assembly 115 may assist in reducing energy consumption while keeping costs low.
  • the internal control systems may operate evaporator fan motor 127 a and condenser fan motor 115 a without requiring additional, expensive, electronic temperature controls with specific relays for this purpose.
  • evaporator fan motor assembly 127 includes an internal control system and condenser fan motor assembly 115 includes an internal control system.
  • the internal control system of evaporator fan motor assembly 127 may be independent of the internal control system of condenser fan motor assembly 115 .
  • evaporator fan motor assembly 127 and/or condenser fan motor assembly 115 do not need to communicate with one another and/or do not need to rely on one another in order to control evaporator fan motor 127 a and/or condenser fan motor 115 b.
  • fan motors 127 a , 115 a of evaporator fan motor assembly 127 and condenser fan motor assembly 115 may be electronically commutated motor(s) (ECMs) that have an internal circuit board modified for the purpose of sensing the compressor line voltage, an in-line circuit, and/or other electric or electronic components (i.e., integrated circuits, microprocessors, memory, etc.) designed for cycling evaporator fan motor 127 a and/or condenser fan motor 115 a between an OFF state (“OFF”) and an ON state (“ON”) until compressor 112 is turned ON again by thermostat 130 .
  • ECMs electronically commutated motor(s)
  • evaporator fan motor 127 a and/or condenser fan motor 115 a can be repeatedly cycled OFF for 5 minutes and then ON for 1 minute.
  • Typical internal ECM motor electronics do not have enough internal board level isolation to properly sense the compressor line voltage, thus condenser fan motor assembly 115 and evaporator fan motor assembly 127 may each incorporate circuit board design and components not found in typical condenser and evaporator fan motor assemblies in order to achieve the board level isolation required for correctly operating condenser fan motor 115 a and evaporator fan motor 127 a.
  • Evaporator fan motor assembly 127 may be electrically connected to line 134 and neutral wire 136 via power supply wire 137 and neutral wire 138 , respectively. Additionally, thermostat 130 may be electrically connected to line 134 . Condenser fan motor assembly 115 and compressor 112 may be wired in parallel between thermostat 130 and neutral wire 136 . As stated above, in various embodiments, thermostat 130 may include a relay and capillary tube for measuring the temperature within storage compartment 24 . When the temperature within storage compartment 24 rises above the desired set temperature, the relay of thermostat 130 closes thereby completing the circuit and tuning ON compressor 112 . A digital control input wire 132 may be connected to the live output side of thermostat 130 and may permit internal control system of evaporator fan motor assembly 115 to sense a line voltage in the circuit when the relay of thermostat 130 closes.
  • the internal control system of condenser fan motor assembly 115 may not require a separate digital control input wire to determine line voltage because the internal control system can sense the line voltage in condenser power line 140 when the relay of thermostat 130 closes.
  • the internal control systems of each of condenser fan motor assembly 115 and evaporator fan motor assembly 127 permit the use of a simple, cheap and reliable mechanical thermostat 130 . Accordingly, condenser fan motor assemblies 115 and/or evaporator fan motor assemblies 127 with internal control systems may be placed into existing refrigerator units without the need for costly external control systems. Thus, existing refrigerator units can be retrofitted with condenser fan motor assemblies 115 and/or evaporator fan motor assemblies 127 having internal control systems and energy efficiency gains may be realized with a low cost.
  • Preliminary testing to date has indicated an estimated energy savings on a typical 115 volt model (two solid door upright refrigerator) of between 15 and 25 percent over current production construction. These numbers may vary based on the volume of storage compartment 24 and the ratio of the size of refrigeration system 110 to the volume of storage compartment 24 . For example, in certain embodiments, larger amounts of energy savings may be realized with refrigeration systems 10 that are more lightly loaded (i.e., where compressor 112 is designed to be OFF for longer periods of time).
  • compressor 112 receives low-pressure, substantially gaseous refrigerant from evaporator 120 through suction line 128 c , pressurizes the refrigerant, and discharges high-pressure, substantially gaseous refrigerant through discharge line 128 a to condenser 114 .
  • condenser 114 heat is removed from the refrigerant, causing the substantially gaseous refrigerant to condense into a substantially liquid refrigerant.
  • the high-pressure, substantially liquid refrigerant is routed through liquid line 128 b to thermal expansion device 118 (e.g., a capillary tube, a thermostatic expansion valve, an electronic expansion valve, etc.), which reduces the pressure of the substantially liquid refrigerant for introduction into evaporator 120 .
  • thermal expansion device 118 e.g., a capillary tube, a thermostatic expansion valve, an electronic expansion valve, etc.
  • the refrigerant absorbs heat from the tubes contained within evaporator 120 and vaporizes as the refrigerant passes through the tubes.
  • Low-pressure, substantially gaseous refrigerant is discharged from the outlet of evaporator 120 through suction line 128 c , and is reintroduced into the inlet of compressor 112 .
  • refrigeration system 110 of refrigerator unit 10 may include an evaporator fan motor assembly 127 having an internal control system for repeatedly cycling evaporator fan motor 127 a between an ON state (“ON”) and an OFF state (“OFF”). This cycling can be intermittent (i.e., the OFF time and the ON time do not need to be equal).
  • evaporator fan motor assembly 127 may include a fan motor 127 a , fan blade(s) 127 b , and an internal control system (not shown) adapted to control the operation of evaporator fan motor 127 a .
  • the internal control system of evaporator fan motor assembly 127 may be adapted to sense the compressor line voltage via digital control input wire 132 (see FIG. 3 ) such that the internal control system may be able to sense when compressor 112 is turned ON or OFF by thermostat 130 . Accordingly, the internal control system may control evaporator fan motor 127 a without the need for an external and/or additional control system.
  • compressor 112 is turned ON by thermostat 130 .
  • the internal control system of evaporator fan motor assembly 127 senses that compressor 112 has turned ON and turns ON evaporator fan motor 127 a causing fan blade(s) 127 b to rotate and blow air across evaporator 120 . Accordingly, evaporator fan motor 127 a can operate continuously while compressor 112 is ON.
  • compressor 112 is turned OFF by thermostat 130 .
  • evaporator fan motor 127 a may remain ON.
  • cooling of storage compartment 24 may continue because residual cool refrigerant remains in evaporator 120 even after compressor 112 stops running.
  • the internal control system of condenser fan motor assembly 127 may include a timer for measuring elapsed time. The timer may be reset each time compressor 112 turns ON.
  • the internal control system of evaporator fan motor assembly 127 may include a processor which may provide a timing function. The timer may be implemented via hardware, software, and/or firmware within the internal control system of evaporator fan motor assembly 127 in any manner known in the art without departing from the scope of the invention.
  • the internal control system of evaporator fan motor assembly 127 turns OFF evaporator fan motor 127 a at step 312 .
  • evaporator fan motor assembly 127 when compressor 112 is turned OFF at step 304 , internal control system of evaporator fan motor assembly 127 turns OFF evaporator fan motor 127 a at step 312 . Accordingly, in certain embodiments, evaporator fan motor 127 a may not continue to remain ON for a second time interval.
  • the internal control system of evaporator fan motor assembly 127 monitors whether compressor 112 has turned ON. As long as compressor 112 remains OFF, evaporator fan motor 127 a may repeatedly cycle ON and OFF, thereby taking advantage of the energy savings by turning OFF evaporator fan motor 127 a for a period of time. However, the temperature in storage compartment 24 may be maintained by turning ON evaporator fan motor 127 a for a period of time. Therefore, while compressor 112 is OFF, the internal control system of evaporator fan motor assembly 127 keeps evaporator fan motor 127 a OFF during a third time interval at step 316 .
  • the internal control system of evaporator fan motor assembly 127 turns ON evaporator fan motor 127 a at step 318 causing fan blade(s) 127 b to rotate and blow air across evaporator 120 . Then at step 320 , the internal control system of evaporator fan motor assembly 127 monitors whether compressor 112 has turned ON. As long as compressor 112 remains OFF, the internal control system of evaporator fan motor assembly 127 keeps evaporator fan motor 127 a ON during a fourth time interval at step 324 .
  • the internal control system of evaporator fan motor assembly 127 turns OFF evaporator fan motor 127 a and the process returns to step 312 .
  • This process may then repeat wherein the internal control system of the evaporator fan motor assembly 127 repeatedly cycles evaporator fan motor 127 a ON and OFF while compressor 112 is OFF.
  • By running evaporator fan motor 127 a during repeated fourth time intervals air will still be circulated across evaporator 120 by fan blade(s) 127 b to maintain the temperature in storage compartment 24 .
  • the heat generated by evaporator fan motor assembly 127 may be reduced, thereby reducing heat transfer from evaporator fan motor assembly 127 into storage compartment 24 .
  • the amount of air required to maintain a uniform temperature in storage compartment 24 during the compressor 112 OFF state may be reduced by as much as a factor of ten (10) as compared to the compressor 112 ON state.
  • step 306 if compressor 112 turns ON at any point, the cycle will be restarted at step 302 and evaporator fan motor 127 a will be turned ON or will remain ON. Accordingly, the compressor 112 ON state may interrupt the intermittent operation of evaporator fan motor assembly 127 at any time.
  • the second, third and fourth intervals of time as described in connection with steps 308 (optional step), 316 , and 322 may be any length of time and may vary according to a variety of design and/or operating parameters including, but not limited to, storage compartment 24 volume, ambient temperatures, storage compartment 24 operating temperature, etc.
  • the second interval of time, as described at step 308 may be about zero seconds to about 1 minute (e.g., about zero seconds, about 5 seconds, about 10 seconds, about 15 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds).
  • the third interval of time, as described at step 316 may be about 1 minute to about 7 minutes (e.g., about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes).
  • the fourth interval of time, as described at step 322 may be about 15 seconds to about 2 minutes (e.g., about 15 seconds, about 30 seconds, about 45 seconds, about 60 seconds, about 1 minute and 15 seconds, about 1 minute and 30 seconds, about 1 minute and 45 seconds, about 2 minutes).
  • refrigeration system 110 of refrigerator unit 10 may additionally or alternatively include a condenser fan motor assembly 115 having an internal control system independent from the internal control system of evaporator fan motor assembly 127 .
  • condenser fan motor assembly 115 may include a fan motor 115 a , fan blade(s) 115 b , and an internal control system (not shown) adapted to control the operation of condenser fan motor 115 a .
  • the internal control system may be adapted to sense the compressor line voltage, such that the internal control system of condenser fan motor assembly 115 may be able to sense when compressor 112 is turned ON or OFF by thermostat 130 . Accordingly, the internal control system of condenser fan motor assembly 115 may control condenser fan motor 115 a without the need for an external and/or additional control system.
  • compressor 112 is turned ON by thermostat 130 .
  • the internal control system of condenser fan motor assembly 115 senses that compressor 112 has turned ON and turns condenser fan motor 115 a ON such that condenser fan motor 115 a and fan blade(s) 115 b run in a REVERSE DIRECTION. This is known as a Reverse-on-Start (ROS) function.
  • ROS Reverse-on-Start
  • the ROS function of condenser fan motor assembly 115 provides advantages over the prior art in that it may assist in keeping condenser 114 clean by blowing accumulated dirt and debris off of the coil (not shown) of condenser 114 during the first mode of operation.
  • a dirty condenser coil can double the energy consumption of refrigeration system 110 in only a few months.
  • a dirty condenser coil can also cause premature compressor 112 failures due to overheating.
  • the internal control system of condenser fan motor assembly 115 continues to run condenser fan motor 115 a and fan blade(s) 115 b in the REVERSE DIRECTION until a first time interval has elapsed as indicated at step 404 .
  • the internal control system of condenser fan motor assembly 115 may include a timer for measuring elapsed time. The timer may be reset each time compressor 112 turns ON.
  • the internal control system of condenser fan motor assembly 115 may include a processor which may provide a timing function. The timer may be implemented via hardware, software, and/or firmware within the internal control system of condenser fan motor assembly 115 in any manner known in the art without departing from the scope of the invention.
  • the first time interval can be from about 5 seconds to about 60 seconds (e.g., about 5 seconds, about 10 seconds, about 15 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds). In certain embodiments, for example, first time interval can be from about 20 seconds to about 35 seconds. In other embodiments, first time interval can be about 30 seconds.
  • the internal control system of condenser fan motor assembly 115 turns condenser fan motor 115 a ON such that condenser fan motor 115 a and fan blade(s) 115 b run in a FORWARD DIRECTION. Accordingly, at this step, condenser fan motor 115 a and fan blade(s) 115 b turn in the “normal direction” while compressor 112 remains ON. At step 408 , compressor 112 is turned OFF by thermostat 130 . At step 410 , the internal control system of condenser fan motor assembly 115 senses that compressor 112 has turned OFF and turns condenser fan motor 115 a OFF. Condenser fan motor 115 a then remains OFF until thermostat 130 turns compressor 112 back ON.
  • condenser fan motor 115 a and fan blade(s) 115 b running in the REVERSE DIRECTION and condenser fan motor 115 a and fan blade(s) 115 b running in the FORWARD DIRECTION. This pause may allow condenser fan motor 115 a and/or fan blade(s) 115 b of condenser fan motor assembly 115 to stop rotating.
  • the pause may be from about 1 second to about 15 seconds (e.g., about 1 second, about 2 seconds, about 3 seconds, about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds).
  • refrigeration system 110 of refrigerator unit 10 may include both an evaporator fan motor assembly 127 and a condenser fan motor assembly 115 wherein each may include a fan motor 127 a , 115 a , fan blade(s) 127 b , 115 b and an independent internal control system (not shown) adapted to control the operation of evaporator fan motor 127 a and condenser fan motor 115 a , respectively.
  • the internal control systems of each of evaporator fan motor assembly 127 and condenser fan motor assembly 115 may be adapted to sense the compressor line voltage, such that the internal control systems may be able to independently sense the compressor 112 ON or OFF state.
  • each of evaporator fan motor assembly 127 and condenser fan motor assembly 115 may control evaporator fan motor 127 a and condenser fan motor 115 a , respectively, without the need for an external and/or additional control system.
  • compressor 112 is turned ON by thermostat 130 .
  • the internal control system of evaporator fan motor assembly 127 senses that compressor 112 has turned ON and turns evaporator fan motor 127 a ON causing fan blade(s) 127 b to rotate and blow air across evaporator 120 .
  • the internal control system of condenser fan motor assembly 115 senses that compressor 112 has turned ON and turns condenser fan motor 115 a ON such that condenser fan motor 115 a and fan blade(s) 115 b run in a REVERSE DIRECTION.
  • the internal control system of condenser fan motor assembly 115 continues to run condenser fan motor 115 a and fan blade(s) 115 b in the REVERSE DIRECTION until a first time interval has elapsed as indicated at step 506 .
  • the internal control system of condenser fan motor assembly 115 may include a timer for measuring elapsed time.
  • the timer may be reset each time compressor 112 turns ON.
  • the internal control system of condenser fan motor assembly 115 may include a processor which may provide a timing function.
  • the timer may be implemented via hardware, software, and/or firmware within the internal control system of condenser fan motor assembly 115 in any manner known in the art without departing from the scope of the invention.
  • the internal control system of condenser fan motor assembly 115 turns ON condenser fan motor 115 a such that condenser fan motor 115 a and fan blade(s) 115 b run in a FORWARD DIRECTION. Accordingly, at this step, condenser fan motor 115 a and fan blade(s) 115 b turn in the “normal direction” while compressor 112 remains ON.
  • compressor 112 is turned OFF by thermostat 130 .
  • the internal control system of condenser fan motor assembly 115 senses that compressor 112 has turned OFF and turns OFF condenser fan motor 115 a . Condenser fan motor 115 a then remains OFF until thermostat 130 turns compressor 112 back ON.
  • condenser fan motor 115 a and fan blade(s) 115 b running in the REVERSE DIRECTION and condenser fan motor 115 a and fan blade(s) 115 b running in the FORWARD DIRECTION. This pause may allow condenser fan motor 115 a and/or fan blade(s) 115 b of condenser fan motor assembly 115 to stop rotating.
  • the pause may be from about 1 second to about 15 seconds (e.g., about 1 second, about 2 seconds, about 3 seconds, about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds).
  • evaporator fan motor 127 a remains ON.
  • the internal control system of condenser fan motor assembly 127 may include a timer for measuring elapsed time. The timer may be reset each time compressor 112 turns ON.
  • the internal control system of evaporator fan motor assembly 127 may include a processor which may provide a timing function.
  • the timer may be implemented via hardware, software, and/or firmware within the internal control system of evaporator fan motor assembly 127 in any manner known in the art without departing from the scope of the invention.
  • the internal control system of evaporator fan motor assembly 127 turns OFF evaporator fan motor 127 a at step 520 .
  • optional steps 514 , 516 and 518 are not performed, when compressor 112 is turned OFF at step 512 , internal control system of evaporator fan motor assembly 127 turns OFF evaporator fan motor 127 a at step 520 . Accordingly, in certain embodiments, evaporator fan motor 127 a may not remain ON for a second time interval.
  • the internal control system of evaporator fan motor assembly 127 monitors whether compressor 112 has turned ON. As long as compressor 112 remains OFF, evaporator fan motor 127 a may repeatedly cycle ON and OFF thereby taking advantage of the energy savings by turning OFF evaporator fan motor 127 a for a period of time. However, the temperature in storage compartment 24 may be maintained by turning evaporator fan motor 127 a ON for a period of time. Therefore, while compressor 112 is OFF, the internal control system of evaporator fan motor assembly 127 keeps evaporator fan motor 127 a OFF during a third time interval at step 524 .
  • the internal control system of evaporator fan motor assembly 127 turns ON evaporator fan motor 127 a at step 526 causing fan blade(s) 127 b to rotate and blow air across evaporator 120 . Then at step 528 , the internal control system of evaporator fan motor assembly 127 monitors whether compressor 112 has turned ON. As long as compressor 112 remains OFF, the internal control system of evaporator fan motor assembly 127 keeps evaporator fan motor 127 a ON during a fourth time interval at step 532 .
  • the internal control system of evaporator fan motor assembly 127 turns OFF evaporator fan motor 127 a and the process returns to step 520 .
  • This process may then repeat wherein the internal control system of the evaporator fan motor assembly 127 intermittently cycles evaporator fan motor 127 a ON and OFF while compressor 112 is OFF.
  • air will still be circulated across evaporator 120 to maintain the temperature in storage compartment 24 .
  • the heat generated by evaporator fan motor assembly 127 may be reduced, thereby reducing heat transfer from evaporator fan motor assembly 127 into storage compartment 24 .
  • the amount of air required to maintain a uniform temperature in storage compartment 24 during the compressor 112 OFF state may be reduced by as much as a factor of 10 as compared to the compressor 112 ON state.
  • step 514 if compressor 112 turns ON at any point, the cycle will be restarted at step 502 and evaporator fan motor 127 a will be turned ON or will remain ON. Accordingly, the compressor 112 ON state may interrupt the intermittent operation of evaporator fan motor assembly 127 at any time.
  • the first, second, third and fourth intervals of time as described in connection with steps 506 , 516 (optional step), 524 , and 530 may be any length of time and may vary according to a variety of design and/or operating parameters including, but not limited to, storage compartment 24 volume, ambient temperatures, storage compartment 24 operating temperature, etc.
  • the first time interval, as described at step 506 can be from about 5 seconds to about 60 seconds (e.g., about 5 seconds, about 10 seconds, about 15 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds). In certain embodiments, for example, first time interval can be from about 20 seconds to about 35 seconds.
  • first time interval can be about 30 seconds.
  • the second interval of time, as described at step 516 may be about zero seconds to about 1 minute (e.g., about zero seconds, about 5 seconds, about 10 seconds, about 15 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds).
  • the third interval of time, as described at step 524 may be about 1 minute to about 7 minutes (e.g., about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes).
  • the fourth interval of time may be about 15 seconds to about 2 minutes (e.g., about 15 seconds, about 30 seconds, about 45 seconds, about 60 seconds, about 1 minute and 15 seconds, about 1 minute and 30 seconds, about 1 minute and 45 seconds, about 2 minutes).
  • FIG. 7 illustrates a time plot of the operating states of compressor 112 , condenser fan motor assembly 115 and evaporator fan motor assembly 127 . While compressor 112 is OFF, condenser fan motor 115 a and evaporator fan motor 127 a are OFF. Compressor 112 is then turned ON by thermostat 130 and the timers of the internal control systems of condenser fan motor assembly 115 and evaporator fan motor assembly 127 are reset to an initial time t 0 .
  • the internal control system of condenser fan motor assembly 115 turns condenser fan motor 115 a ON in a REVERSE DIRECTION and the internal control system of evaporator fan motor assembly 127 turns evaporator fan motor 127 a ON.
  • the internal control system of condenser fan motor assembly 115 turns condenser fan motor 115 a ON in a FORWARD DIRECTION.
  • compressor 112 is turned OFF by thermostat 130 and the internal control system of condenser fan motor assembly 115 senses that compressor 112 has turned OFF and turns condenser fan motor 115 a OFF.
  • internal control system of evaporator fan motor assembly 127 senses that compressor 112 has turned OFF and may optionally keep evaporator fan motor 127 a running for a second time interval from t 2 to t 3 .
  • the internal control system of evaporator fan motor assembly 127 turns evaporator fan motor 127 a OFF.
  • evaporator fan motor 127 a may be OFF from t 2 to t 3 (see FIG. 7A ).
  • evaporator fan motor 127 a remains OFF.
  • the internal control system of evaporator fan motor assembly 127 turns evaporator fan motor 127 a ON and evaporator fan motor 127 a remains ON until a fourth time interval has elapsed (from t 4 to t 5 ).
  • the internal control system of evaporator fan motor assembly 127 then cycles evaporator fan motor 127 a ON and OFF during successive third (from t 5 to t 6 ) and fourth (from t 6 to t 7 ) time intervals until compressor 112 turns back ON wherein the process restarts and the time is reset to t 0 .
  • third and fourth time intervals Although only two successive third and fourth time intervals are illustrated in FIGS. 7 and 7A , it will be understood by one skilled in the art that any number of third and fourth time intervals may occur where evaporator fan motor assembly intermittently operates between the compressor being ON without departing from the scope of the invention.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Devices That Are Associated With Refrigeration Equipment (AREA)
US14/656,241 2014-03-13 2015-03-12 Internal control systems of evaporator and condenser fan motor assemblies of a refrigeration system in a refrigerator unit Abandoned US20150260448A1 (en)

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US11340003B2 (en) 2018-08-14 2022-05-24 Hoffman Enclosures, Inc. Thermal monitoring for cooling systems
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11340003B2 (en) 2018-08-14 2022-05-24 Hoffman Enclosures, Inc. Thermal monitoring for cooling systems
US20220252324A1 (en) * 2021-02-09 2022-08-11 Standex International Corporation Refrigeration system with enveloping air circulation around product chamber
US11698216B2 (en) * 2021-02-09 2023-07-11 Standex International Corporation Refrigeration system with enveloping air circulation around product chamber
US20230341169A1 (en) * 2021-02-09 2023-10-26 Standex International Corporation Refrigeration system with enveloping air circulation around product chamber
CN113803957A (zh) * 2021-09-27 2021-12-17 珠海格力电器股份有限公司 制冷设备的控制方法、装置、控制器和制冷设备

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WO2015179009A3 (fr) 2016-01-21

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