WO2009018624A1 - Refrigerant filling apparatus and method - Google Patents

Refrigerant filling apparatus and method Download PDF

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Publication number
WO2009018624A1
WO2009018624A1 PCT/AU2008/001154 AU2008001154W WO2009018624A1 WO 2009018624 A1 WO2009018624 A1 WO 2009018624A1 AU 2008001154 W AU2008001154 W AU 2008001154W WO 2009018624 A1 WO2009018624 A1 WO 2009018624A1
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WO
WIPO (PCT)
Prior art keywords
refrigerant
temperature
refrigeration system
change
charging
Prior art date
Application number
PCT/AU2008/001154
Other languages
French (fr)
Inventor
Angelo Talarico
Ian Robert Cocks
Original Assignee
Ariazone International Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2007904280A external-priority patent/AU2007904280A0/en
Application filed by Ariazone International Pty Ltd filed Critical Ariazone International Pty Ltd
Publication of WO2009018624A1 publication Critical patent/WO2009018624A1/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25BREFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B45/00Arrangements for charging or discharging refrigerant
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60HARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00Heating, cooling or ventilating [HVAC] devices
    • B60H1/00507Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00585Means for monitoring, testing or servicing the air-conditioning
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25BREFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2345/00Details for charging or discharging refrigerants; Service stations therefor
    • F25B2345/001Charging refrigerant to a cycle

Definitions

  • the present invention relates to refrigeration systems, such as air conditioning systems and, in particular, relates to apparatus and method for aiding the filling or re- filling (charging) of such systems with refrigerant.
  • Fig. 1 shows a modern, yet prior art, refrigeration system 100, such as an air conditioner, which includes a compressor 110, a condenser 120, a receiver/dryer 130, a pressure regulator 140, an evaporator 150 and an accumulator 160 as the main components thereof.
  • Those components 110-160 are connected together in a closed loop which. further typically includes with various maintenance ports, protection devices and other components connected within the loop, but not illustrated in Fig. 1.
  • a suction or inlet pipe 112 of the compressor 110 receives low pressure gas from a fluid output of the evaporator 150, and uses energy from a driving source of the compressor 110 (eg. electric motor or combustion engine, not illustrated) to produce high-pressure gas which passes from a discharge or outlet tube 114 of the compressor 110 into the condenser 120.
  • the condenser 120 is typically an array of tubing thermally-connected with heat transfer fins over which forced air flows to transfer heat from the high pressure gas thereby causing the gas to change state (condense) into liquid form. This removes heat from the refrigeration system 100, transferring that heat into the flow of air.
  • the condenser 120 is generally located outside the space to be cooled.
  • the cooled liquid then passes through the receiver/dryer 130 which separates any remaining gas from the liquid to ensure that only liquid is passed onto the pressure regulator 140 via the loop.
  • the dryer section of the receiver/dryer component 140 removes moisture and filters dirt that may have become trapped in the system 100.
  • the filtered liquid from the receiver/dryer 130 then passes into the pressure regulator 140, of which there are several types in common use. These include thermal expansion valves, orifice tubes, to name just two.
  • the pressure regulator 140 regulates the liquid pressure and flow into the evaporator 150 to maintain an ideal operating temperature.
  • Regulated refrigeration fluid entering the evaporator 150 which is located in the space to be cooled, absorbs heat from air passed over fins of the evaporator, which causes the refrigerant liquid to boil and change from liquid to gas. The gas then enters the suction side 112 of the compressor 110 and begins the cycle again. Gas from the output evaporator 150 is sometimes passed through an accumulator 160 to separate liquid from gas and filter the stream for dirt and moisture.
  • the loop must be first evacuated by drawing the system pressure down close to absolute zero
  • a refrigerant processor 200 is typically a portable machine that contains a compressor 210, a vacuum pump 230, a refrigerant tank 220, a recovery tank 240 (for recovered gas) and various control 260 and monitoring 250 components.
  • the processor 200 has a range of operations including automatic recovery, recharge, etc.
  • the vacuum pump 232 is coupled into the loop of the system 100 and is operated to evacuate (used) refrigerant into the recovery tank 240.
  • the compressor 210 is operated to charge the system 100 with (new) refrigerant from the supply tank 220.
  • the operator will observe the liquid level within the system 100 via a viewing window arranged in the loop, for example within the receiver/dryer 130, or between the receiver/dryer 130 and the pressure regulator 140.
  • Most refrigerant processors 200 use a manual method to determine the correct quantity of refrigerant gas for a specific air conditioner (refrigeration) system. Some use manual entry of the quantity (volume or mass) of refrigerant by assuming the operator knows the correct figure for that system. Other processors use a table where the operator selects the make/model of refrigeration system and the processor has a pre-programmed table of quantities for each combination. These are collectively indicated at 270 in Fig. 1. Both of these methods are cumbersome and risky. The manual method is prone to operator error by accidental entry of the wrong amount, or deliberate if the correct amount is not known.
  • the make/model table method is dependent on the table including details of the particular system, which is often not the case for new refrigeration systems being charged by older machines, and the selection of the correct table value by the operator. Also, operator observation via a viewing window is prone to error as the inside surface of the window may be subject to contamination making accurate determination of fluid presence difficult.
  • a means of determining the correct quantity of gas to be dispensed In order to better automate the process of recharging gas into a refrigeration system using an external refrigerant processor unit, presently disclosed is a means of determining the correct quantity of gas to be dispensed. Specifically described is a fully- automatic means of determining refrigerant charge level by monitoring rapid temperature change within the refrigeration loop, such as a temperature drop at the compressor inlet (suction) pipe.
  • a method of charging a refrigeration system supplies a substantially evacuated refrigerant loop of the refrigeration system with a refrigerant fluid and monitors at least a temperature associated with a fluid line forming part of a refrigerant loop of the refrigeration system. A relatively rapid change in the temperature between two substantive equilibrium values is detected, and in response thereto, the charging of the refrigeration system is ceased.
  • the rapid change is typically a drop in temperature from a start of charge substantive equilibrium to an end of charge substantive equilibrium.
  • the fluid line forms a connection between an output of an evaporator and an input of a compressor of the system.
  • the rapid change can be detected by evaluating a real-time derivative of temperature values obtained by the monitoring. Further the rapid change may be detected by comparing the real-time derivative value with a threshold value.
  • the threshold value is typically determined from at least an ambient temperature at which the charging is performed. Desirably the threshold value is further determined using at least one of ambient humidity and the type of refrigerant being used.
  • the refrigeration system is in operation during the performance of the method.
  • the method may further include detecting a further change associated with the supply of refrigerant to the system and comparing the detected further change with the detected rapid change to identify a time at which charging is to be ceased.
  • the further change may be a change in state from liquid to gas of the refrigerant, and the detecting thereof comprises passing an ultrasonic wave across the flow of refrigerant in the system and detecting a rapid change in transit time of the ultrasonic wave between transmission and reception.
  • a refrigerant processor system for implementing the method and a computer readable medium having a computer program recorded thereon, said program being executable by computer apparatus within a refrigerant processor to control a charging of a refrigeration system with refrigerant.
  • Fig. 1 is a schematic block diagram representation of a prior art refrigeration system and refrigerant processor
  • Fig. 2 is a similar schematic block diagram representation including a refrigerant processor according to the present disclosure
  • Fig. 3 is a temperature/time plot for charging the system of Fig. 2 at a relatively high ambient temperature
  • Fig. 4 is a temperature/time plot for charging the system of Fig. 2 at a relatively low ambient temperature
  • Fig. 5 is a schematic block diagram of an exemplary monitoring and control unit of a refrigerant processor according to the present disclosure
  • Fig. 6 illustrates a charging method implemented by the arrangements of Figs. 2 and 5; and Fig. 7 illustrates an ultrasonic method of charge state.
  • an automatic end-of-charge determination method that is effective, accurate, and which can be implemented at low-cost and does not require elaborate placement of complex measurement devices beyond the expertise of non-skilled operators.
  • the present inventors have determined that the end-of-charge in a refrigeration may be determined with reliable accuracy by monitoring a temperature associated with the refrigerant during charging and detecting a relatively rapid change in that temperature, for example evidenced by a temperature drop at the compressor inlet.
  • the specific implementation described here uses two temperature measurement points and one humidity point.
  • Fig. 2 shows the refrigeration system 100 of Fig. 1 connected to refrigerant processor 300 according to the present disclosure.
  • the connection 190 between the accumulator 160 and compressor 112 in the system 100 to be (re)charged does not require the isolation valve 192.
  • connecting lines 314 and 334 from a compressor 310 and pump 330 respectively of the processor 300 desirably include respective electrically actuable isolation valves 316 and 336.
  • the valves 316 and 336 may be removably coupled to the connection 190 in a manner corresponding to existing apparatus, such as in Fig. 1.
  • the valves 316 and 336 receive control signals 318 and 338 respectively from a control unit 360.
  • a temperature sensor 352 is placed on the connection 190 at the compressor suction inlet pipe 112.
  • the temperature sensor 352 is desirably clipped or otherwise removably secured to the inlet 112, to detect the temperature of the inlet pipe 112 which, since such is usually manufactured of copper tubing, has a temperature well-associated with that of the refrigerant passing through that location in the loop of the system 100.
  • a monitor unit 350 couples a sensed temperature signal 354 from the sensor 352 to the control unit 360.
  • a discharge/recover operation operation of the system 100 is disabled, and the valve 316 is closed and the valve 336 opened via signals from the control unit 360.
  • the vacuum pump 330 is then operated to draw (used) refrigerant from the system 100 and into the recovery tank 340.
  • discharge/recover is deemed complete and the valve 336 is closed via the control unit 360.
  • the air conditioning system 100 is operated with at least the compressor 112 running, and preferably forced air running across each of the condenser 120 and evaporator 150.
  • the valve 316 is then opened by the control unit 360 and the compressor 310 is enabled to supply (new) refrigerant from the tank 320 via the connection 314 to the inlet pipe 112.
  • the processor 300 starts supplying refrigerant to the system 100
  • the compressor inlet 112 receives small quantities of low pressure refrigerant gas.
  • the temperature detected by the sensor 352 may either rise or fall slightly depending on any one or more of ambient, system and gas temperatures.
  • the compressor 110 and condenser 120 will produce an increasing amount of compressed liquid in that portion of the loop from the condenser 120 through the receiver/dryer 130, pressure regulator 140 and into the evaporator 150.
  • the evaporator 150 must be full of boiling refrigerant for heat to be absorbed by the change-of-state from liquid to gas.
  • a partially gas-filled evaporator 150 will not operate at optimum efficiency.
  • FIG. 3 shows a typical temperature profile during charging of a motor vehicle air conditioning system in an ambient temperature of 44°C.
  • the temperature sensor 352 measured a starting temperature equilibrium 402 of about 35 0 C, and a rapid fall 404 of approximately 10°C at the end-of-charge point.
  • An end-of-charge equilibrium temperature 406 of about 20°C was then detected.
  • Independent measurement of the quantity of refrigerant gas applied determined that the correct amount was reached at 176.0 seconds.
  • the rapid temperature drop occurred over a period of about 25-40 seconds, with the steepest part of the profile occurring for about 5 seconds, with a 10°C drop occurring over 35 seconds (ie. about 66% of the temperature drop occurring in about 20% of the charging time).
  • Fig. 3 shows a typical temperature profile during charging of a motor vehicle air conditioning system in an ambient temperature of 44°C.
  • the temperature sensor 352 measured a starting temperature equilibrium 402 of about 35 0 C, and a rapid fall 404 of approximately 10°C at the end-of-charge point.
  • FIG. 4 shows a charge cycle for the same system in an ambient temperature of approximately 4°C.
  • a rapid drop 414 of about 5°C was detected between a starting temperature 412 of about 9°C and an end temperature 416 of about 3°C.
  • the charging period was about 55 seconds and the rapid drop occurred over about 4 to 6 seconds (ie. about 85% of the temperature change occurring within about 10% of the charging time).
  • neither the start (402, 412) or end (406, 416) temperatures remain fixed, but are nevertheless at respective substantive equilibria.
  • Figs. 3 and 4 illustrate that the rate of change of the temperature is relatively rapid in comparison to other temperature changes during the charging cycle.
  • the shape of the curve, and therefore the end-of-charge point (time), varies with ambient temperature.
  • the shape of the curve will also alter with ambient humidity and refrigerant gas composition.
  • the fall in temperature at the end-of-charge point is lower in magnitude (approx. 6°C) at the lower ambient temperature compared to the higher ambient temperature curve. It follows that one can detect the relatively rapid temperature drop to identify end-of-charge. Further, based on the measured charging period it was determined that the rate of change of temperature (the temperature derivative) is better indicative of end-of- charge. Particularly, end-of-charge substantially coincided with the maximum slope of the temperature curve (ie. a peak in the derivative). This peak may be used in association with other measurements to determine end-of-charge.
  • determination of end-of-charge is performed by software executing within the control unit 360, which differentiates the compressor suction temperature at the compressor inlet 112 in real-time to determine the rate-of- change as the charge cycle progresses. Numerical differentiation is applied to real-time data samples of the sensed temperature. When the rate-of-change (fall) (the derivative) reaches a particular magnitude or threshold value (increasing negative), the charge cycle is stopped or ceased by closing the valve 316 and disabling the compressor 310.
  • the threshold value is desirably determined based on the ambient temperature, humidity, charge time and, potentially, identified refrigerant gas type. An operator of the refrigerant processor 300 can then be advised by appropriate means, such as an audible and/or visible indication (alarm).
  • Safety monitoring is achieved by establishing maximum charge time, again based on ambient temperature and gas conditions.
  • the shape of the temperature curve which can be retained as data samples in computer memory, can also be used to identify various component faults in the air conditioning system and the curves can be provided to the operator to assist in repair.
  • Fig. 5 shows a detailed schematic block diagram representation of a monitoring and control unit 500 which may be used in the refrigerant processor 300 of Fig. 2, to substitute for the components 350 and 360.
  • the unit 500 is operative to perform a method of charging a refrigeration system and by which the method is substantially performed using software programmed into the unit 500 on one or more computer readable media formed therein.
  • the control unit 500 includes a computer processor 505, an operator input device 513 such as a keyboard, computer memory 506 which can include storage media such as random access memory and read only memory for retaining the software, an audio-video interface arrangement 507 for coupling to a video display unit 514 and an audio output 517.
  • a printer 515 may be included so that results of the charging process may be recorded in hardcopy form.
  • An FO interface unit 508 is provided which has an input from an analogue to digital converter (ADC) 512.
  • the ADC 512 is configured to receive the temperature sense signal 354 from the temperature sensor 352, as well as an ambient temperature value from an ambient temperature sensor 516 and a humidity value from a humidity sensor 511.
  • the I/O interface 508 provides a number of outputs as indicated to each of the valves 316 and 336 and each of the compressor 310 and pump 330. At elevated ambient humidity levels, moisture on the evaporator 150 acts as an insulator, thereby preventing heat loss as the refrigeration fluid fills the system 100. At low humidity, this insulating effect is considerably reduced.
  • the rate of temperature drop experienced by the temperature sensor 352 decreases due to the fluid receiving heat from ambient air through the evaporator 150. Measuring the ambient humidity and temperature via the sensors 511 and 516 respectively allows the software to adjust the end-of-charge detection threshold in response to the rate of heat gain.
  • Software, including executable code, by which the method of re-charging is implemented is preferably stored in non-volatile memory (eg. ROM) within the memory unit 506 and is read and executed via the processor 505 by means of a system bus 504 to which each of the devices 505, 507, 508, 515, 513 and 506 connect.
  • the processor 505 may receive temperature samples via the connection 354 and ADC 512 which may be stored in volatile memory (eg. RAM) within the memory unit 506.
  • the processor 505 is configured, using the stored temperature values, to numerically differentiate those values in real time to identify the end-of-charge and thus control the various components of the refrigerant processor 300 according to the method of re-charging.
  • Particular status such as a plot of the temperature curve similar to Figs. 3 and 4, of the process may be displayed in real-time using the video display 514 with any visual alarms also being displayed thereon. Alarms may alternatively or additionally be audibly output via the loud speaker 517.
  • Fig. 6 is a flowchart of a preferred method 600 of refrigerant re-processing which includes both the discharge/recover and re-charge cycles.
  • the particular end-of-charge detection methods described herein are operative during the (re)charge cycle.
  • the method 600 is substantially indicative of a software control program executable by the processor 505 of the unit 500.
  • an entry start point 602 may be established upon the operator having connected the various components as shown in Fig. 2 and pressing a "start" button or the like on the keyboard 513.
  • the unit 500 at step 604 closes the valve 316 and opens the valve 336.
  • the evacuation or discharge/recover of the refrigeration system 100 is then performed at step 606 by operating the vacuum pump 330.
  • Step 608 monitors the vacuum pressure at the pump 330 and this can be via a vacuum pressure line 520 also input to the ADC 512 as seen in Fig. 5. If the required vacuum pressure is not reached, control returns to step 608, thereby continually testing the vacuum pressure value. When the required vacuum pressure is reached, control proceeds to step 610 which then closes the valve 336 thus isolating the vacuum pump 330 and stops the pump 330. At step 612, the valve 316 for the compressor 310 is opened via a signal 316 and the compressor 310 is then started at step 614. Whilst the compressor 310 is operating, step 616 takes at least one temperature sample. Temperature sampling may be performed at any reasonable interval, such as one sample every 0.1 seconds with the sample being stored in the memory 506.
  • the present inventors consider that the temperature sampling period should be shorter than about 0.5 seconds for accurate numerical differentiation of the temperature values. Using modern microprocessor technologies, sampling may be performed at much higher rates if desired.
  • a numerical derivative is calculated using a number of consecutive temperature samples, this calculation being performed in software via the processor 505 accessing the samples from the memory 506.
  • the current derivative value is compared by the processor 505 with a predetermined threshold associated with the particular refrigeration system 100 and the refrigerant being used.
  • the threshold may also be calculated by the processor 505 using the ambient temperature from the sensor 513 and the humidity from the sensor 511. If that threshold has not been reached, control returns to step 616 where one or more further temperature samples are taken. When step 620 finds that the real-time derivative has exceeded the threshold, end-of charge is considered met and control passes to step 622 which closes the valve 316 which ceases the charging of the system 100. The compressor 310 is then stopped at step 624 and the recharge cycle ends at step 626. The refrigerant processor 300 may then be disconnected from the refrigeration system 100.
  • Another method for detecting end-of-charge is to monitor a pipeline 135 connecting the receiver/dryer 130 to the pressure regulator 140.
  • the refrigeration system 100 is at optimal charge when a full column of liquid exists at the input to the pressure regulator, i.e. the pipe is completely full of fluid with no gas present. This is how the prior art visual "window" examination is performed.
  • a burst of ultrasonic energy can be applied to one side of the pipeline 135 and received at the opposite side, or reflected back to the original transducer.
  • An example of such an arrangement is shown in Fig. 7 where, placed either side of the pipeline 135 are ultrasonic transducers 702 and 704.
  • An ultrasonic transmitter 706 causes the transducer 702 to emit a burst of ultrasound across the fluid flow which is detected at the transducer 704 using a receiver 708.
  • a control module 710 manages transmission and reception to output a transit time ( ⁇ ) 712 for each burst. Transit time values 712 obtained during charging can be input to the ADC 512 of the unit 500 and numerically differentiated as above to determine end-of-charge.
  • the transition time taken for the ultrasonic wave burst to travel across the stream can be monitored and a curve generated of individual transition times versus real time.
  • the pipeline 135 may be considered to be full of liquid and the charge cycle can be stopped.
  • the arrangements described are applicable to the refrigeration and air- conditioning industries and particularly for the re-charging of such refrigeration and air- conditioning systems. This is particularly important in respect of the re-charging of motor vehicle air-conditioning or refrigeration systems (eg. for trucks or containers) for example, and other mobile apparatus. Nevertheless, the methods described herein may be readily applied to fixed refrigeration systems such as domestic and commercial air- conditioning systems and other refrigeration systems.

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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)

Abstract

A method (600)of charging a refrigeration system (100) includes supplying (614) a substantially evacuated refrigerant loop of the refrigeration system with a refrigerant fluid. The method monitors (616, 352) at least a temperature associated with a fluid line forming part of a refrigerant loop of the refrigeration system and detects (620) a relatively rapid change (404, 414) in the temperature between two substantive equilibrium values (402,406; 412, 416). In response to the detection of the rapid change, the method ceases (622) the charging of the refrigeration system.

Description

REFRIGERANT FILLING APPARATUS AND METHOD
Technical Field
The present invention relates to refrigeration systems, such as air conditioning systems and, in particular, relates to apparatus and method for aiding the filling or re- filling (charging) of such systems with refrigerant.
Background
Fig. 1 shows a modern, yet prior art, refrigeration system 100, such as an air conditioner, which includes a compressor 110, a condenser 120, a receiver/dryer 130, a pressure regulator 140, an evaporator 150 and an accumulator 160 as the main components thereof. Those components 110-160 are connected together in a closed loop which. further typically includes with various maintenance ports, protection devices and other components connected within the loop, but not illustrated in Fig. 1.
In a cooling-mode of operation, a suction or inlet pipe 112 of the compressor 110 receives low pressure gas from a fluid output of the evaporator 150, and uses energy from a driving source of the compressor 110 (eg. electric motor or combustion engine, not illustrated) to produce high-pressure gas which passes from a discharge or outlet tube 114 of the compressor 110 into the condenser 120. The condenser 120 is typically an array of tubing thermally-connected with heat transfer fins over which forced air flows to transfer heat from the high pressure gas thereby causing the gas to change state (condense) into liquid form. This removes heat from the refrigeration system 100, transferring that heat into the flow of air. The condenser 120 is generally located outside the space to be cooled.
The cooled liquid then passes through the receiver/dryer 130 which separates any remaining gas from the liquid to ensure that only liquid is passed onto the pressure regulator 140 via the loop. The dryer section of the receiver/dryer component 140 removes moisture and filters dirt that may have become trapped in the system 100.
The filtered liquid from the receiver/dryer 130 then passes into the pressure regulator 140, of which there are several types in common use. These include thermal expansion valves, orifice tubes, to name just two. The pressure regulator 140 regulates the liquid pressure and flow into the evaporator 150 to maintain an ideal operating temperature.
Regulated refrigeration fluid entering the evaporator 150, which is located in the space to be cooled, absorbs heat from air passed over fins of the evaporator, which causes the refrigerant liquid to boil and change from liquid to gas. The gas then enters the suction side 112 of the compressor 110 and begins the cycle again. Gas from the output evaporator 150 is sometimes passed through an accumulator 160 to separate liquid from gas and filter the stream for dirt and moisture.
During maintenance or installation of such a refrigeration system 100, the loop must be first evacuated by drawing the system pressure down close to absolute zero
(vacuum), and then charged with an appropriate quantity of refrigerant gas. The correct charge quantity is based on performance of the particular system, rather than a "fill-to- the-top" method like that used with filling a fuel tank of a motor vehicle. An overfilled refrigeration system can cause damage to components, and an undercharged system will exhibit poor performance.
Generally maintenance is performed using a refrigerant processor 200, also seen in Fig. 1, which is typically a portable machine that contains a compressor 210, a vacuum pump 230, a refrigerant tank 220, a recovery tank 240 (for recovered gas) and various control 260 and monitoring 250 components. The processor 200 has a range of operations including automatic recovery, recharge, etc. Typically, the vacuum pump 232 is coupled into the loop of the system 100 and is operated to evacuate (used) refrigerant into the recovery tank 240. When such is completed, the compressor 210 is operated to charge the system 100 with (new) refrigerant from the supply tank 220. Often the operator will observe the liquid level within the system 100 via a viewing window arranged in the loop, for example within the receiver/dryer 130, or between the receiver/dryer 130 and the pressure regulator 140.
Most refrigerant processors 200 use a manual method to determine the correct quantity of refrigerant gas for a specific air conditioner (refrigeration) system. Some use manual entry of the quantity (volume or mass) of refrigerant by assuming the operator knows the correct figure for that system. Other processors use a table where the operator selects the make/model of refrigeration system and the processor has a pre-programmed table of quantities for each combination. These are collectively indicated at 270 in Fig. 1. Both of these methods are cumbersome and risky. The manual method is prone to operator error by accidental entry of the wrong amount, or deliberate if the correct amount is not known. The make/model table method is dependent on the table including details of the particular system, which is often not the case for new refrigeration systems being charged by older machines, and the selection of the correct table value by the operator. Also, operator observation via a viewing window is prone to error as the inside surface of the window may be subject to contamination making accurate determination of fluid presence difficult.
Modern workshops often have very few trained staff capable of correctly servicing air conditioning systems. Workshop owners often purchase a refrigerant processor machine on the basis that it will do the job on its own with little user interaction. Manual entry of refrigerant gas quantity, either directly or via table, is a significant cause of incorrect charges, poor air conditioner performance and component damage.
Summary It is an object of the present invention to substantially overcome, or at least ameliorate, one or more deficiencies of known systems.
In order to better automate the process of recharging gas into a refrigeration system using an external refrigerant processor unit, presently disclosed is a means of determining the correct quantity of gas to be dispensed. Specifically described is a fully- automatic means of determining refrigerant charge level by monitoring rapid temperature change within the refrigeration loop, such as a temperature drop at the compressor inlet (suction) pipe.
In accordance with one aspect of the present disclosure there is provided a method of charging a refrigeration system. The method supplies a substantially evacuated refrigerant loop of the refrigeration system with a refrigerant fluid and monitors at least a temperature associated with a fluid line forming part of a refrigerant loop of the refrigeration system. A relatively rapid change in the temperature between two substantive equilibrium values is detected, and in response thereto, the charging of the refrigeration system is ceased.
The rapid change is typically a drop in temperature from a start of charge substantive equilibrium to an end of charge substantive equilibrium. Desirably the fluid line forms a connection between an output of an evaporator and an input of a compressor of the system. The rapid change can be detected by evaluating a real-time derivative of temperature values obtained by the monitoring. Further the rapid change may be detected by comparing the real-time derivative value with a threshold value. The threshold value is typically determined from at least an ambient temperature at which the charging is performed. Desirably the threshold value is further determined using at least one of ambient humidity and the type of refrigerant being used. Typically the refrigeration system is in operation during the performance of the method.
The method may further include detecting a further change associated with the supply of refrigerant to the system and comparing the detected further change with the detected rapid change to identify a time at which charging is to be ceased. The further change may be a change in state from liquid to gas of the refrigerant, and the detecting thereof comprises passing an ultrasonic wave across the flow of refrigerant in the system and detecting a rapid change in transit time of the ultrasonic wave between transmission and reception.
Also disclosed is a refrigerant processor system for implementing the method and a computer readable medium having a computer program recorded thereon, said program being executable by computer apparatus within a refrigerant processor to control a charging of a refrigeration system with refrigerant. Brief Description of the Drawings
At least one embodiment of the present invention will now be described with reference to the drawings in which:
Fig. 1 is a schematic block diagram representation of a prior art refrigeration system and refrigerant processor; Fig. 2 is a similar schematic block diagram representation including a refrigerant processor according to the present disclosure;
Fig. 3 is a temperature/time plot for charging the system of Fig. 2 at a relatively high ambient temperature;
Fig. 4 is a temperature/time plot for charging the system of Fig. 2 at a relatively low ambient temperature; Fig. 5 is a schematic block diagram of an exemplary monitoring and control unit of a refrigerant processor according to the present disclosure;
Fig. 6 illustrates a charging method implemented by the arrangements of Figs. 2 and 5; and Fig. 7 illustrates an ultrasonic method of charge state.
Detailed Description including Best Mode
Disclosed is an automatic end-of-charge determination method that is effective, accurate, and which can be implemented at low-cost and does not require elaborate placement of complex measurement devices beyond the expertise of non-skilled operators. The present inventors have determined that the end-of-charge in a refrigeration may be determined with reliable accuracy by monitoring a temperature associated with the refrigerant during charging and detecting a relatively rapid change in that temperature, for example evidenced by a temperature drop at the compressor inlet. The specific implementation described here uses two temperature measurement points and one humidity point.
Fig. 2 shows the refrigeration system 100 of Fig. 1 connected to refrigerant processor 300 according to the present disclosure. hi this implementation, the connection 190 between the accumulator 160 and compressor 112 in the system 100 to be (re)charged does not require the isolation valve 192. Rather connecting lines 314 and 334 from a compressor 310 and pump 330 respectively of the processor 300 desirably include respective electrically actuable isolation valves 316 and 336. The valves 316 and 336 may be removably coupled to the connection 190 in a manner corresponding to existing apparatus, such as in Fig. 1. The valves 316 and 336 receive control signals 318 and 338 respectively from a control unit 360. A temperature sensor 352 is placed on the connection 190 at the compressor suction inlet pipe 112. The temperature sensor 352 is desirably clipped or otherwise removably secured to the inlet 112, to detect the temperature of the inlet pipe 112 which, since such is usually manufactured of copper tubing, has a temperature well-associated with that of the refrigerant passing through that location in the loop of the system 100. A monitor unit 350 couples a sensed temperature signal 354 from the sensor 352 to the control unit 360.
For a discharge/recover operation, operation of the system 100 is disabled, and the valve 316 is closed and the valve 336 opened via signals from the control unit 360. The vacuum pump 330 is then operated to draw (used) refrigerant from the system 100 and into the recovery tank 340. When a predetermined vacuum pressure, detected at the pump 334 for example, is reached, discharge/recover is deemed complete and the valve 336 is closed via the control unit 360.
During a charging cycle, the air conditioning system 100 is operated with at least the compressor 112 running, and preferably forced air running across each of the condenser 120 and evaporator 150. With the evacuated system 100 operating and the valve 336 closed, the valve 316 is then opened by the control unit 360 and the compressor 310 is enabled to supply (new) refrigerant from the tank 320 via the connection 314 to the inlet pipe 112. Initially, as the processor 300 starts supplying refrigerant to the system 100, the compressor inlet 112 receives small quantities of low pressure refrigerant gas. The temperature detected by the sensor 352 may either rise or fall slightly depending on any one or more of ambient, system and gas temperatures.
As the system 100 receives more gas, the compressor 110 and condenser 120 will produce an increasing amount of compressed liquid in that portion of the loop from the condenser 120 through the receiver/dryer 130, pressure regulator 140 and into the evaporator 150. For efficient operation, and thus optimal charging, the evaporator 150 must be full of boiling refrigerant for heat to be absorbed by the change-of-state from liquid to gas. A partially gas-filled evaporator 150 will not operate at optimum efficiency. As charging progresses, and cold expanded gas reaches the sensor 352, the temperature falls rapidly after which an equilibrium is reached between the gas temperature and the pipe/wall, which is in communication with ambient air. The observed charging temperature profile will then stabilise at a value significantly below the temperature at the start of the charging cycle. Fig. 3 shows a typical temperature profile during charging of a motor vehicle air conditioning system in an ambient temperature of 44°C. In this example, the temperature sensor 352 measured a starting temperature equilibrium 402 of about 350C, and a rapid fall 404 of approximately 10°C at the end-of-charge point. An end-of-charge equilibrium temperature 406 of about 20°C was then detected. Independent measurement of the quantity of refrigerant gas applied determined that the correct amount was reached at 176.0 seconds. As will be appreciated from Fig. 3, the rapid temperature drop occurred over a period of about 25-40 seconds, with the steepest part of the profile occurring for about 5 seconds, with a 10°C drop occurring over 35 seconds (ie. about 66% of the temperature drop occurring in about 20% of the charging time). Fig. 4 shows a charge cycle for the same system in an ambient temperature of approximately 4°C. Here a rapid drop 414 of about 5°C was detected between a starting temperature 412 of about 9°C and an end temperature 416 of about 3°C. The charging period was about 55 seconds and the rapid drop occurred over about 4 to 6 seconds (ie. about 85% of the temperature change occurring within about 10% of the charging time). As seen from Figs. 3 and 4, neither the start (402, 412) or end (406, 416) temperatures remain fixed, but are nevertheless at respective substantive equilibria. Further, Figs. 3 and 4 illustrate that the rate of change of the temperature is relatively rapid in comparison to other temperature changes during the charging cycle.
The shape of the curve, and therefore the end-of-charge point (time), varies with ambient temperature. The shape of the curve will also alter with ambient humidity and refrigerant gas composition.
Comparing Figs. 3 and 4, the fall in temperature at the end-of-charge point, although still easily distinguished, is lower in magnitude (approx. 6°C) at the lower ambient temperature compared to the higher ambient temperature curve. It follows that one can detect the relatively rapid temperature drop to identify end-of-charge. Further, based on the measured charging period it was determined that the rate of change of temperature (the temperature derivative) is better indicative of end-of- charge. Particularly, end-of-charge substantially coincided with the maximum slope of the temperature curve (ie. a peak in the derivative). This peak may be used in association with other measurements to determine end-of-charge.
In a preferred implementation, determination of end-of-charge is performed by software executing within the control unit 360, which differentiates the compressor suction temperature at the compressor inlet 112 in real-time to determine the rate-of- change as the charge cycle progresses. Numerical differentiation is applied to real-time data samples of the sensed temperature. When the rate-of-change (fall) (the derivative) reaches a particular magnitude or threshold value (increasing negative), the charge cycle is stopped or ceased by closing the valve 316 and disabling the compressor 310. The threshold value is desirably determined based on the ambient temperature, humidity, charge time and, potentially, identified refrigerant gas type. An operator of the refrigerant processor 300 can then be advised by appropriate means, such as an audible and/or visible indication (alarm).
Safety monitoring is achieved by establishing maximum charge time, again based on ambient temperature and gas conditions. The shape of the temperature curve, which can be retained as data samples in computer memory, can also be used to identify various component faults in the air conditioning system and the curves can be provided to the operator to assist in repair.
Fig. 5 shows a detailed schematic block diagram representation of a monitoring and control unit 500 which may be used in the refrigerant processor 300 of Fig. 2, to substitute for the components 350 and 360. The unit 500 is operative to perform a method of charging a refrigeration system and by which the method is substantially performed using software programmed into the unit 500 on one or more computer readable media formed therein. As seen, the control unit 500 includes a computer processor 505, an operator input device 513 such as a keyboard, computer memory 506 which can include storage media such as random access memory and read only memory for retaining the software, an audio-video interface arrangement 507 for coupling to a video display unit 514 and an audio output 517. A printer 515 may be included so that results of the charging process may be recorded in hardcopy form. An FO interface unit 508 is provided which has an input from an analogue to digital converter (ADC) 512. The ADC 512 is configured to receive the temperature sense signal 354 from the temperature sensor 352, as well as an ambient temperature value from an ambient temperature sensor 516 and a humidity value from a humidity sensor 511. The I/O interface 508 provides a number of outputs as indicated to each of the valves 316 and 336 and each of the compressor 310 and pump 330. At elevated ambient humidity levels, moisture on the evaporator 150 acts as an insulator, thereby preventing heat loss as the refrigeration fluid fills the system 100. At low humidity, this insulating effect is considerably reduced. Therefore, the rate of temperature drop experienced by the temperature sensor 352 decreases due to the fluid receiving heat from ambient air through the evaporator 150. Measuring the ambient humidity and temperature via the sensors 511 and 516 respectively allows the software to adjust the end-of-charge detection threshold in response to the rate of heat gain.
Software, including executable code, by which the method of re-charging is implemented is preferably stored in non-volatile memory (eg. ROM) within the memory unit 506 and is read and executed via the processor 505 by means of a system bus 504 to which each of the devices 505, 507, 508, 515, 513 and 506 connect. During performance of the method, the processor 505 may receive temperature samples via the connection 354 and ADC 512 which may be stored in volatile memory (eg. RAM) within the memory unit 506. The processor 505 is configured, using the stored temperature values, to numerically differentiate those values in real time to identify the end-of-charge and thus control the various components of the refrigerant processor 300 according to the method of re-charging. Particular status, such as a plot of the temperature curve similar to Figs. 3 and 4, of the process may be displayed in real-time using the video display 514 with any visual alarms also being displayed thereon. Alarms may alternatively or additionally be audibly output via the loud speaker 517.
Fig. 6 is a flowchart of a preferred method 600 of refrigerant re-processing which includes both the discharge/recover and re-charge cycles. The particular end-of-charge detection methods described herein are operative during the (re)charge cycle. The method 600 is substantially indicative of a software control program executable by the processor 505 of the unit 500. hi the method 600 of Fig. 6, an entry start point 602 may be established upon the operator having connected the various components as shown in Fig. 2 and pressing a "start" button or the like on the keyboard 513. Initially, the unit 500 at step 604 closes the valve 316 and opens the valve 336. The evacuation or discharge/recover of the refrigeration system 100 is then performed at step 606 by operating the vacuum pump 330.
Step 608 monitors the vacuum pressure at the pump 330 and this can be via a vacuum pressure line 520 also input to the ADC 512 as seen in Fig. 5. If the required vacuum pressure is not reached, control returns to step 608, thereby continually testing the vacuum pressure value. When the required vacuum pressure is reached, control proceeds to step 610 which then closes the valve 336 thus isolating the vacuum pump 330 and stops the pump 330. At step 612, the valve 316 for the compressor 310 is opened via a signal 316 and the compressor 310 is then started at step 614. Whilst the compressor 310 is operating, step 616 takes at least one temperature sample. Temperature sampling may be performed at any reasonable interval, such as one sample every 0.1 seconds with the sample being stored in the memory 506. Given the steepness of the graphs of Figs. 3 and 4 at the end-of-charge time, the present inventors consider that the temperature sampling period should be shorter than about 0.5 seconds for accurate numerical differentiation of the temperature values. Using modern microprocessor technologies, sampling may be performed at much higher rates if desired. At step 618, a numerical derivative is calculated using a number of consecutive temperature samples, this calculation being performed in software via the processor 505 accessing the samples from the memory 506. Various algorithms exist for calculating or evaluating numerical derivatives. At step 620, the current derivative value is compared by the processor 505 with a predetermined threshold associated with the particular refrigeration system 100 and the refrigerant being used. The threshold may also be calculated by the processor 505 using the ambient temperature from the sensor 513 and the humidity from the sensor 511. If that threshold has not been reached, control returns to step 616 where one or more further temperature samples are taken. When step 620 finds that the real-time derivative has exceeded the threshold, end-of charge is considered met and control passes to step 622 which closes the valve 316 which ceases the charging of the system 100. The compressor 310 is then stopped at step 624 and the recharge cycle ends at step 626. The refrigerant processor 300 may then be disconnected from the refrigeration system 100.
Another method for detecting end-of-charge is to monitor a pipeline 135 connecting the receiver/dryer 130 to the pressure regulator 140. In this approach, the refrigeration system 100 is at optimal charge when a full column of liquid exists at the input to the pressure regulator, i.e. the pipe is completely full of fluid with no gas present. This is how the prior art visual "window" examination is performed.
According to another aspect of the present disclosure, a burst of ultrasonic energy can be applied to one side of the pipeline 135 and received at the opposite side, or reflected back to the original transducer. An example of such an arrangement is shown in Fig. 7 where, placed either side of the pipeline 135 are ultrasonic transducers 702 and 704. An ultrasonic transmitter 706 causes the transducer 702 to emit a burst of ultrasound across the fluid flow which is detected at the transducer 704 using a receiver 708. A control module 710 manages transmission and reception to output a transit time (τ) 712 for each burst. Transit time values 712 obtained during charging can be input to the ADC 512 of the unit 500 and numerically differentiated as above to determine end-of-charge. Given the speed of sound is constant in the pipe walls, is slower in fluid, and is slower again in gas, the transition time taken for the ultrasonic wave burst to travel across the stream can be monitored and a curve generated of individual transition times versus real time. When the transition time graph falls and remains at the lower level for a given period, the pipeline 135 may be considered to be full of liquid and the charge cycle can be stopped.
Industrial Applicability The arrangements described are applicable to the refrigeration and air- conditioning industries and particularly for the re-charging of such refrigeration and air- conditioning systems. This is particularly important in respect of the re-charging of motor vehicle air-conditioning or refrigeration systems (eg. for trucks or containers) for example, and other mobile apparatus. Nevertheless, the methods described herein may be readily applied to fixed refrigeration systems such as domestic and commercial air- conditioning systems and other refrigeration systems.
The foregoing describes only some embodiments of the present invention and modifications and/or changes may be made thereto without departing from the scope of the present invention, the embodiments being illustrative and not restrictive. For example, whilst the present disclosure describes two approaches for detecting end-of-charge (ie. temperature transition, or transit time change), both may be combined to provide for redundancy of the detection of end-of-charge. Further, whilst the above described placement of the various sensors only in particular locations within the refrigeration loop, it will be apparent that placement of the sensors at other locations may be used to achieve similar or complementary detection arrangements. For example, the sensor 352 may be positioned anywhere in the suction pipe of the compressor 110, between the output of the evaporator 150 and the input 112 of the compressor 110, although close to the evaporator outlet is desirable.
(Australia only) In the context of the specification, the word "comprising" means "including principally but not necessarily solely" or "having" or "including", and not "consisting only of. Variations of the word "comprising", such as "comprise" and "comprises" have correspondingly varied meanings.

Claims

CLAIMS:
1. A method of charging a refrigeration system, said method comprising the steps of: supplying a substantially evacuated refrigerant loop of said refrigeration system with a refrigerant fluid; monitoring at least a temperature associated with a fluid line forming part of a refrigerant loop of said refrigeration system; detecting a relatively rapid change in the temperature between two substantive equilibrium values; and in response to the detection of the rapid change, ceasing the charging of the refrigeration system.
2. A method according to claim 1 wherein said rapid change is a drop in temperature from a start of charge substantive equilibrium to an end of charge substantive equilibrium.
3. A method according to claim 1 or 2 wherein the fluid line forms a connection between an output of an evaporator and an input of a compressor of the system.
4. A method according to claim 1, 2 or 3 wherein said rapid change is detected by evaluating a real-time derivative of temperature values obtained by said monitoring.
5. A method according to claim 4 wherein said rapid change is detected by comparing the real time derivative value with a threshold value.
6. A method according to claim 5 wherein the threshold value is determined from at least an ambient temperature at which the charging is performed.
7. A method according to claim 6 wherein the threshold value is further determined using at least one of ambient humidity and the type of refrigerant being used.
8. A method according to any one of the preceding claims wherein said refrigeration system is in operation during the method.
9. A method according to any one of the preceding claims further comprising detecting a further change associated with the supply of refrigerant to the system and comparing the detected further change with the detected rapid change to identify a time at which charging is to be ceased.
10. A method according to claim 9 wherein the further change further comprises a change in state from liquid to gas, and the detecting thereof comprises passing an ultrasonic wave across the flow of refrigerant in the system and detecting a rapid change in transit time of the ultrasonic wave between transmission and reception.
11. A refrigerant processor system comprising: a compressor to supply refrigerant to a substantially evacuated refrigeration system; at least one temperature sensor configured to be coupled to the refrigeration system to monitor a temperature associated with refrigerant flowing in the refrigeration system; and a control unit for detecting a relatively rapid change in the monitored 5 temperature between two substantive equilibrium values, and in response to the detection of the rapid change, to cease a supply of refrigerant by the compressor to the refrigeration system.
12. A refrigerant processor according to claim 11 wherein said control unit i0 comprises a computer system to obtain real time temperature samples from said temperature sensor and from the samples to determine a real time rate of change of the sampled temperature, the real time rate of change being compared with a threshold value to thereby detect the relatively rapid change.
is 13. A refrigerant processor according to claim 11 or 12 wherein the rapid change is a drop in temperature, said temperature sensor being coupled at an inlet of a compressor of said refrigeration system whilst the refrigeration system is in operation.
14. A refrigerant processor according to claim 12 or 13 further comprising a further 0 air temperature sensor by which an ambient air temperature is determined, at least said ambient air temperature being used by the control unit to determine said threshold value.
15. A computer readable storage medium having a computer program recorded thereon, said program being executable by computer apparatus within a refrigerant processor to control a charging of a refrigeration system with refrigerant, said program comprising: code means for monitoring a temperature sensed from a location in a refrigerant loop of the refrigeration system;
5 code means for evaluating a real time rate of change of the monitored temperature; and code means for comparing the real time rate of change with a threshold value such that when the later is exceeded, charging of the refrigeration system is ceased.
i0
16. A method of charging a refrigeration system substantially as described herein with reference to Figs. 2-4 and 6, or Figs. 2 - 6, or Figs. 2 and 7, of the drawings.
17. A refrigerant processor substantially as described herein with reference to Fig. 2, or Figs. 2 and 5, or Figs. 2, 5 and 6, or Figs. 2 and7 or the drawings. is
18. A control program for a refrigerant processor substantially as described herein with reference to Fig. 6 of the drawings.
PCT/AU2008/001154 2007-08-09 2008-08-08 Refrigerant filling apparatus and method WO2009018624A1 (en)

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Publication number Priority date Publication date Assignee Title
CN104956165A (en) * 2012-12-31 2015-09-30 博世汽车服务解决方案公司 Refrigerant removal device and method
US10228172B2 (en) 2013-08-01 2019-03-12 Carrier Corporation Refrigerant level monitor for refrigeration system
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CN114393975A (en) * 2022-01-27 2022-04-26 岚图汽车科技有限公司 Exhaust method and device of vehicle whole vehicle heat management loop
CN114393975B (en) * 2022-01-27 2023-05-30 岚图汽车科技有限公司 Exhaust method and device of whole vehicle thermal management loop

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