US20170102157A1

US20170102157A1 - Air conditioner units and methods for determining indoor room temperatures

Info

Publication number: US20170102157A1
Application number: US14/879,173
Authority: US
Inventors: Paul Goodjohn; Robert Jules Lafleur
Original assignee: Haier US Appliance Solutions Inc
Current assignee: Haier US Appliance Solutions Inc
Priority date: 2015-10-09
Filing date: 2015-10-09
Publication date: 2017-04-13

Abstract

Air conditioner units and methods for determining indoor room temperatures are provided. A method includes calculating a difference between a first temperature received from a first temperature sensor and a second temperature received from a second temperature sensor. The first and second temperature sensors are disposed within an indoor portion of an air conditioner unit, the first temperature sensor disposed proximate an indoor heat exchanger of the air conditioner unit, the second temperature sensor spaced from the indoor heat exchanger relative to the first temperature sensor. The method further includes modifying the second temperature based on the difference to obtain a corrected temperature, and outputting the corrected temperature.

Description

FIELD OF THE INVENTION

The present disclosure relates generally to air conditioner units and methods for operating air conditioner units, and more particularly to methods and apparatus for air conditioner units to accurately determine indoor air temperatures.

BACKGROUND OF THE INVENTION

Air conditioner units are conventionally utilized to adjust the temperature within structures such as dwellings and office buildings. In particular, one-unit type room air conditioner units may be utilized to adjust the temperature in, for example, a single room or group of rooms of a structure. A typical such air conditioner unit includes an indoor portion and an outdoor portion. The indoor portion is generally located indoors, and the outdoor portion is generally located outdoors. Accordingly, the air conditioner unit generally extends through a wall, window, etc. of the structure.
In the outdoor portion of a conventional air conditioner unit, a compressor that operates a refrigerating cycle is provided. At the back of the outdoor portion, an outdoor heat exchanger connected to the compressor is disposed, and facing the outdoor heat exchanger, an outdoor fan for cooling the outdoor heat exchanger is provided. At the front of the indoor portion of a conventional air conditioner unit, an air inlet is provided, and above the air inlet, an air outlet is provided. A blower fan and a heating unit may additionally be provided in the indoor portion. Between the blower fan and heating unit and the air inlet, an indoor heat exchanger connected to the compressor is provided.
When cooling operation starts, the compressor is driven to operate the refrigerating cycle, with the indoor heat exchanger serving as a cold-side evaporator of the refrigerating cycle, and the outdoor heat exchanger as a hot-side condenser. The outdoor heat exchanger is cooled by the outdoor fan to dissipate heat. As the blower fan is driven, the air inside the room flows through the air inlet into the air passage, and the air has its temperature lowered by heat exchange with the indoor heat exchanger, and is then blown into the room through the air outlet. In this way, the room is cooled.
When heating operation starts, the compressor may be driven to operate a heat pump cycle, with the indoor heat exchanger serving as a hot-side condenser and the outdoor heat exchanger as a cold-side evaporator. The heating unit may additionally be operated to raise the temperature of air in the air passage. As the blower fan is driven, the air inside the room flows through the air inlet into the air passage, and the air has its temperature raised by heat exchange with the indoor heat exchanger, and is then blown into the room through the air outlet. In this way, the room is heated.
Further, conventional air conditioner units include a bulkhead which is positioned between the indoor portion and outdoor portion, and thus generally separates the components within the indoor portion from the components in the outdoor portion. Various components may additionally be connected to the bulkhead, such as the blower fan and heating unit.
A typical air conditioner unit includes one or more temperature sensors for sensing various indoor and outdoor temperatures. For example, an indoor temperature sensor may be provided for measuring the indoor temperature. Further, in some embodiments, an additional sensor may be provided in the indoor portion for measuring the temperature of the coils of the indoor heat exchanger.
In some cases, issues may arise with the accuracy of the indoor ambient temperature readings of the indoor temperature sensor. For example, the sensor may become inaccurate when the blower fan is shut off and significant airflow through the indoor heat exchanger is ceased. Specifically, the temperature of the indoor heat exchanger and coils thereof may bias the readings of the indoor temperature sensor. Such biasing may be caused by the outdoor temperature and attempts by the sealed thermodynamic assembly to obtain pressure equalization. For example, when the air conditioner unit is operating in a refrigerating cycle, the indoor temperature sensor may initially sense a temperature lower than the indoor ambient temperature, due to the temperature of the refrigerant in the indoor heat exchanger. The indoor temperature sensor may then gradually transition to sensing a temperature higher than the indoor ambient temperature, due to the outdoor (presumably hotter) air heating the refrigerant. When the air conditioner unit is operating in a heat pump cycle, the indoor temperature sensor may initially sense a temperature higher than the indoor ambient temperature, due to the temperature of the refrigerant in the indoor heat exchanger. The indoor temperature sensor may then gradually transition to sensing a temperature lower than the indoor ambient temperature, due to the outdoor (presumably colder) air cooling the refrigerant. Additionally, biasing can occur due to heat retention (or heat transmission to the indoor heat exchanger) by the coils of the heating unit when the blower fan is shut off.
Accordingly, improved air conditioner units and methods for determining indoor room temperatures are desired. In particular, methods and apparatus which facilitate accurate indoor temperature readings would be advantageous.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In accordance with one embodiment, an air conditioner unit is provided. The air conditioner unit includes an outdoor heat exchanger disposed in an outdoor portion, an indoor heat exchanger disposed in an indoor portion, and a bulkhead disposed between the outdoor heat exchanger and the indoor heat exchanger along a transverse direction, the bulkhead defining the indoor portion and the outdoor portion. The air conditioner unit further includes a first temperature sensor disposed within the indoor portion and proximate the indoor heat exchanger, and a second temperature sensor disposed within the indoor portion and spaced from the indoor heat exchanger relative to the first temperature sensor. The air conditioner unit further includes a controller in communication with the first temperature sensor and the second temperature sensor. The controller is configured for calculating a difference between a first temperature received from the first temperature sensor and a second temperature received from the second temperature sensor, modifying the second temperature based on the difference to obtain a corrected temperature, and outputting the corrected temperature.
In accordance with another embodiment, a method for determining an indoor room temperature is provided. The method includes calculating a difference between a first temperature received from a first temperature sensor and a second temperature received from a second temperature sensor. The first and second temperature sensors are disposed within an indoor portion of an air conditioner unit, the first temperature sensor disposed proximate an indoor heat exchanger of the air conditioner unit, the second temperature sensor spaced from the indoor heat exchanger relative to the first temperature sensor. The method further includes modifying the second temperature based on the difference to obtain a corrected temperature, and outputting the corrected temperature.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides a perspective view of an air conditioner unit, with a room front exploded from a remainder of the air conditioner unit for illustrative purposes, in accordance with one embodiment of the present disclosure;

FIG. 2 is a perspective view of components of an indoor portion of an air conditioner unit in accordance with one embodiment of the present disclosure;

FIG. 3 is a rear perspective view of a bulkhead assembly in accordance with one embodiment of the present disclosure;

FIG. 4 is another perspective view of components of an indoor portion of an air conditioner unit in accordance with one embodiment of the present disclosure;

FIG. 5 is a cross-sectional view of components of an indoor portion of an air conditioner unit in accordance with one embodiment of the present disclosure; and

FIG. 6 is a flow chart illustrating a method in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
Referring now to FIG. 1, an air conditioner unit 10 is provided. The air conditioner unit 10 is a one-unit type air conditioner, also conventionally referred to as a room air conditioner. The unit 10 includes an indoor portion 12 and an outdoor portion 14, and generally defines a vertical direction V, a lateral direction L, and a transverse direction T. Each direction V, L, T is perpendicular to each other, such that an orthogonal coordinate system is generally defined.
A housing 20 of the unit 10 may contain various other components of the unit 10. Housing 20 may include, for example, a rear grill 22 and a room front 24 which may be spaced apart along the transverse direction by a wall sleeve 26. The rear grill 22 may be part of the outdoor portion 14, which the room front 24 is part of the indoor portion 12. Components of the outdoor portion 14, such as an outdoor heat exchanger 30, outdoor fan (not shown), and compressor 32 may be housed within the wall sleeve 26. A casing 34 may additionally enclose the outdoor fan, as shown.
Referring now also to FIG. 2, indoor portion 12 may include, for example, an indoor heat exchanger 40, a blower fan 42, and a heating unit 44. These components may, for example, be housed behind the room front 24. Additionally, a bulkhead 46 may generally support and/or house various other components or portions thereof of the indoor portion 12, such as the blower fan 42 and the heating unit 44. Bulkhead 46 may generally separate and define the indoor portion 12 and outdoor portion 14.
Outdoor and indoor heat exchangers 30, 40 may be components of a thermodynamic assembly which may alternately be operated as a refrigeration assembly (and thus perform a refrigeration cycle) or a heat pump (and thus perform a heat pump cycle). The assembly may, for example, further include compressor 32 and an expansion valve, both of which may be in fluid communication with the heat exchangers 30, 40 to flow refrigerant therethrough as is generally understood. When the assembly is operating in a cooling mode and thus performs a refrigeration cycle, the indoor heat exchanger 40 acts as an evaporator and the outdoor heat exchanger 30 acts as a condenser. When the assembly is operating in a heating mode and thus performs a heat pump cycle, the indoor heat exchanger 40 acts as a condenser and the outdoor heat exchanger 30 acts as an evaporator. The outdoor and indoor heat exchangers 30, 40 may each include coils 31, 41, as illustrated, through which a refrigerant may flow for heat exchange purposes, as is generally understood.
Bulkhead 46 may include various peripheral surfaces that define an interior 50 thereof. For example, and additionally referring to FIG. 3, bulkhead 46 may include a first sidewall 52 and a second sidewall 54 which are spaced apart from each other along the lateral direction L. A rear wall 56 may extend laterally between the first sidewall 52 and second sidewall 54. The rear wall 56 may, for example, include an upper portion 60 and a lower portion 62. Upper portion 60 may for example have a generally curvilinear cross-sectional shape, and may accommodate a portion of the blower fan 42 when blower fan 42 is housed within the interior 50. Lower portion 62 may have a generally linear cross-sectional shape, and may be positioned below upper portion 60 along the vertical direction V. Rear wall 56 may further include an indoor facing surface 64 and an opposing outdoor facing surface. The indoor facing surface 64 may face the interior 50 and indoor portion 12, and the outdoor facing surface 66 may face the outdoor portion 14.
Bulkhead 46 may additionally extend between a top end 61 and a bottom end 63 along vertical axis V. Upper portion 60 may, for example, include top end 61, while lower portion 62 may, for example, include bottom end 63.
Bulkhead 46 may additionally include, for example, an air diverter 68, which may extend between the sidewalls 52, 54 along the lateral direction L and which may flow air therethrough.
In exemplary embodiments, blower fan 42 may be a tangential fan. Alternatively, however, any suitable fan type may be utilized. Blower fan 42 may include a blade assembly 70 and a motor 72. The blade assembly 70, which may include one or more blades disposed within a fan housing 74, may be disposed at least partially within the interior 50 of the bulkhead 46, such as within the upper portion 60. As shown, blade assembly 70 may for example extend along the lateral direction L between the first sidewall 52 and the second sidewall 54. The motor 72 may be connected to the blade assembly 70, such as through the housing 74 to the blades via a shaft. Operation of the motor 72 may rotate the blades, thus generally operating the blower fan 42. Further, in exemplary embodiments, motor 72 may be disposed exterior to the bulkhead 46. Accordingly, the shaft may for example extend through one of the sidewalls 52, 54 to connect the motor 72 and blade assembly 70.
Heating unit 44 in exemplary embodiments includes one or more heater banks 80. Each heater bank 80 may be operated as desired to produce heat. In some embodiments as shown, three heater banks 80 may be utilized. Alternatively, however, any suitable number of heater banks 80 may be utilized. Each heater bank 80 may further include at least one heater coil or coil pass 82, such as in exemplary embodiments two heater coils or coil passes 82. Alternatively, other suitable heating elements may be utilized.
The operation of air conditioner unit 10 including compressor 32 (and thus the thermodynamic assembly generally) blower fan 42, heating unit 44, and other suitable components may be controlled by a processing device such as a controller 85. Controller 85 may be in communication (via for example a suitable wired or wireless connection) to such components of the air conditioner unit 10. By way of example, the controller 85 may include a memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of unit 10. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor.
Unit 10 may additionally include a control panel 87 and one or more user inputs 89, which may be included in control panel 87. The user inputs 89 may be in communication with the controller 85. A user of the unit 10 may interact with the user inputs 89 to operate the unit 10, and user commands may be transmitted between the user inputs 89 and controller 85 to facilitate operation of the unit 10 based on such user commands. A display 88 may additionally be provided in the control panel 87, and may be in communication with the controller 85. Display 88 may, for example be a touchscreen or other text-readable display screen, or alternatively may simply be a light that can be activated and deactivated as required to provide an indication of, for example, an event or setting for the unit.
Referring now to FIGS. 1, 4 and 5, a first temperature sensor 92 and a second temperature sensor 94 may be disposed within the indoor portion 12. Each temperature sensor may be configured to sense the temperature of its surroundings. The temperature sensors 92, 94 may be in communication with the controller 85, and may transmit temperatures sensed thereby to the controller 85.
First temperature sensor 92 may be disposed proximate the indoor heat exchanger 40 (such as relative to the second temperature sensor 94). For example, in some embodiments, first temperature sensor 92 may be in contact with the indoor heat exchanger 40, such as with a coil 41 thereof. Second temperature sensor 94 may be spaced from the indoor heat exchanger 40, such as in the transverse direction T. For example, the second temperature sensor 94 may be in contact with the room front 24, as illustrated in FIG. 1.
Referring now also to FIG. 6, the present disclosure may further be directed to methods 100 for determining indoor air temperatures. Such methods may advantageously utilize temperatures sensed by and obtained from the first and second temperature sensors 92, 94. In exemplary embodiments, controller 85 may be operable to perform various steps of a method in accordance with the present disclosure.
For example, a method 100 may include the step 110 determining whether the indoor heat exchanger 40 is in a heating mode or a cooling mode. For example, controller 85 may, based on instructions transmitted thereby to the compressor 32 and thermodynamic assembly generally, sense whether current operation is in a heating mode or a cooling mode. The current mode of operation may, for example, determine the manner in which various subsequent steps are carried out. Notably, the thermodynamic assembly being generally in a particular mode does not require that the assembly generally is active. Rather, being in a particular mode may require only that the thermodynamic assembly is configured for activation in that particular mode and/or was active in that particular mode immediately prior to such determination by controller 85.
Method 100 may further include, for example, the step 120 of calculating a difference 122 between a first temperature 102 received from the first temperature sensor 92 and a second temperature 104 received from the second temperature sensor 94. The received temperatures 102, 104 may be temperatures sensed by the sensors 92, 94 at the same time. Such step may occur, for example, when the blower fan 42 is not operating, such as immediately after heating or cooling operations (i.e. immediately after active operation of the thermodynamic assembly). In some embodiments, such step may occur only when the blower fan 42 is not operating. In these embodiments, for example, the second temperature 104 may be the output temperature when the blower fan 42 is operating.
For example, when the indoor heat exchanger 40 is in the cooling mode, step 120 may include subtracting the second temperature 104 from the first temperature 102. When the indoor heat exchanger 40 is in the heating mode, step 120 may include subtracting the first temperature 102 from the second temperature 104.
Notably, in some embodiments, the calculating step 120 may only occur in the case of a particular temperature differential. For example, when the indoor heat exchanger 40 is in the cooling mode, the calculating step 120 in some embodiments may only occur when the first temperature 102 is greater than the second temperature 104. When the indoor heat exchanger 40 is in the heating mode, the calculating step 120 in some embodiments may only occur when the second temperature 104 is greater than the first temperature 102.
Method 100 may further include, for example, the step 130 of applying a predetermined correction factor 132 to the difference 122 to obtain a corrected difference 132. The predetermined correction factor 132 may, for example, be an empirically determined amount, such as a percentage, and may for example, be empirically determined based on various temperature, temperature ranges and/or indoor-outdoor temperature differences. Step 130 may include, for example, multiplying the difference 122 by the predetermined correction factor 132. Typically, such application may result in a corrected difference 132 that is less than the difference 122.
Method 100 may further include, for example, the step 140 of modifying the second temperature 104 based on the difference 122 to obtain a corrected temperature 142. In embodiments wherein the step 130 is include in the method, the second temperature 104 may be modified based on the corrected difference 132 to obtain the corrected temperature 142. For example, when the indoor heat exchanger 40 is in the cooling mode, the modifying step 140 may include decreasing the second temperature 104 based on the difference 122 (or corrected difference 132) to obtain the corrected temperature 142. In other words, the difference 122 (or corrected difference 132) may be subtracted from the second temperature 104 to obtain the corrected temperature 142. When the indoor heat exchanger 40 is in the heating mode, the modifying step 140 may include increasing the second temperature 104 based on the difference 122 (or corrected difference 132) to obtain the corrected temperature 142. In other words, the difference 122 (or corrected difference 132) may be added to the second temperature 104 to obtain the corrected temperature 142.
Method 100 may further include, for example, the step 150 of outputting the corrected temperature 142. The corrected temperature 142 may, for example, be output to the display 88. Further, the corrected temperature 142 may be output for use in other functions of the unit 10, such as in determining when to activate the thermodynamic assembly for further heating or cooling.
Accordingly, units 10 and methods 100 in accordance with the present disclosure advantageously provide improved accuracy of indoor temperature readings. Such improvement is advantageously provided by offsetting sensed indoor temperatures by the second temperature sensor 94 using sensed temperatures by the first temperature sensor 92 in situations wherein biasing of the sensed indoor temperature may occur. Improved resulting temperature readings and resulting operation of the unit 10 may result.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

What is claimed is:

1. An air conditioner unit, comprising:

an outdoor heat exchanger disposed in an outdoor portion;

an indoor heat exchanger disposed in an indoor portion;

a bulkhead disposed between the outdoor heat exchanger and the indoor heat exchanger along a transverse direction, the bulkhead defining the indoor portion and the outdoor portion,

a first temperature sensor disposed within the indoor portion and proximate the indoor heat exchanger;

a second temperature sensor disposed within the indoor portion and spaced from the indoor heat exchanger relative to the first temperature sensor; and

a controller in communication with the first temperature sensor and the second temperature sensor, the controller configured for:

calculating a difference between a first temperature received from the first temperature sensor and a second temperature received from the second temperature sensor;

modifying the second temperature based on the difference to obtain a corrected temperature; and

outputting the corrected temperature.

2. The air conditioner unit of claim 1, wherein the controller is further configured for applying a predetermined correction factor to the difference to obtain a corrected difference, and wherein the second temperature is modified based on the corrected difference to obtain the corrected temperature.

3. The air conditioner unit of claim 1, wherein the controller is further configured for determining whether the indoor heat exchanger is in a heating mode or a cooling mode.

4. The air conditioner unit of claim 3, wherein the calculating step comprises subtracting the second temperature from the first temperature when the indoor heat exchanger is in the cooling mode.

5. The air conditioner unit of claim 3, wherein the modifying step comprises decreasing the second temperature based on the difference when the indoor heat exchanger is in the cooling mode.

6. The air conditioner unit of claim 3, wherein the calculating step occurs only when the first temperature is greater than the second temperature when the indoor heat exchanger is in the cooling mode.

7. The air conditioner unit of claim 3, wherein the calculating step comprises subtracting the first temperature from the second temperature when the indoor heat exchanger is in the heating mode.

8. The air conditioner unit of claim 3, wherein the modifying step comprises increasing the second temperature based on the difference when the indoor heat exchanger is in the heating mode.

9. The air conditioner unit of claim 3, wherein the calculating step occurs only when the second temperature is greater than the first temperature when the indoor heat exchanger is in the heating mode.

10. The air conditioner unit of claim 1, wherein the first temperature sensor is in contact with the indoor heat exchanger.

11. The air conditioner unit of claim 1, wherein the first temperature sensor is in contact with a coil of the indoor heat exchanger.

12. The air conditioner unit of claim 1, wherein the second temperature sensor is spaced from the indoor heat exchanger along the transverse direction.

13. The air conditioner unit of claim 1, further comprising a blower fan and a heating unit each disposed at least partially within an interior of the bulkhead.

14. A method for determining an indoor room temperature, the method comprising:

calculating a difference between a first temperature received from a first temperature sensor and a second temperature received from a second temperature sensor, the first and second temperature sensors disposed within an indoor portion of an air conditioner unit, the first temperature sensor disposed proximate an indoor heat exchanger of the air conditioner unit, the second temperature sensor spaced from the indoor heat exchanger relative to the first temperature sensor;

outputting the corrected temperature.

15. The method of claim 14, further comprising applying a predetermined correction factor to the difference to obtain a corrected difference, and wherein the second temperature is modified based on the corrected difference to obtain the corrected temperature.

16. The method of claim 14, further comprising determining whether the indoor heat exchanger is in a heating mode or a cooling mode.

17. The method of claim 16, wherein the calculating step comprises subtracting the second temperature from the first temperature when the indoor heat exchanger is in the cooling mode.

18. The method of claim 16, wherein the calculating step occurs only when the first temperature is greater than the second temperature when the indoor heat exchanger is in the cooling mode.

19. The method of claim 16, wherein the calculating step comprises subtracting the first temperature from the second temperature when the indoor heat exchanger is in the heating mode.

20. The method of claim 16, wherein the calculating step occurs only when the second temperature is greater than the first temperature when the indoor heat exchanger is in the heating mode.