WO2015079242A2 - Diagnostic de défaillance pour échangeur de chaleur - Google Patents

Diagnostic de défaillance pour échangeur de chaleur Download PDF

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Publication number
WO2015079242A2
WO2015079242A2 PCT/GB2014/053524 GB2014053524W WO2015079242A2 WO 2015079242 A2 WO2015079242 A2 WO 2015079242A2 GB 2014053524 W GB2014053524 W GB 2014053524W WO 2015079242 A2 WO2015079242 A2 WO 2015079242A2
Authority
WO
WIPO (PCT)
Prior art keywords
heat exchanger
temperature
ambient air
microprocessor
use according
Prior art date
Application number
PCT/GB2014/053524
Other languages
English (en)
Other versions
WO2015079242A3 (fr
Inventor
Philip Lambert
Colin HULL
Original Assignee
Elstat Electronics 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
Application filed by Elstat Electronics Ltd filed Critical Elstat Electronics Ltd
Priority to CN201480063106.4A priority Critical patent/CN105745504A/zh
Priority to GB1610452.3A priority patent/GB2536161B/en
Priority to MX2016006929A priority patent/MX2016006929A/es
Priority to BR112016011302A priority patent/BR112016011302A2/pt
Priority to EP14806371.2A priority patent/EP3074706A2/fr
Publication of WO2015079242A2 publication Critical patent/WO2015079242A2/fr
Publication of WO2015079242A3 publication Critical patent/WO2015079242A3/fr
Priority to US15/137,122 priority patent/US20160238332A1/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D29/00—Arrangement or mounting of control or safety devices
    • F25D29/008—Alarm 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
    • F25B49/005—Arrangement or mounting of control or safety devices of 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
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/21—Temperatures
    • F25B2700/2103—Temperatures near a heat exchanger
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/21—Temperatures
    • F25B2700/2106—Temperatures of fresh outdoor air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2700/00—Sensing or detecting of parameters; Sensors therefor
    • F25B2700/21—Temperatures
    • F25B2700/2116—Temperatures of a condenser
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2265/00—Safety or protection arrangements; Arrangements for preventing malfunction
    • F28F2265/10—Safety or protection arrangements; Arrangements for preventing malfunction for preventing overheating, e.g. heat shields

Definitions

  • the present invention relates to the fault diagnosis of a heat exchanger in which ambient air temperature and heat exchanger temperature are measured.
  • Refrigeration may be defined as lowering the temperature of an enclosed space by removing heat from that space and transferring it elsewhere.
  • the work of heat transport is typically driven by heat, magnetism, electricity, or other means.
  • Refrigeration has many applications, including, but not limited to: household refrigerators, industrial freezers, cryogenics, and air conditioning. Heat pumps may use the heat output of the refrigeration process and also may be designed to be reversible, but are otherwise similar to refrigeration units.
  • the vapour-compression cycle is used in most household refrigerators as well as in many large commercial and industrial refrigeration systems.
  • the vapour-compression cycle uses a circulating liquid refrigerant as the medium which absorbs and removes heat from the space to be cooled and subsequently rejects that heat elsewhere.
  • a typical, single-stage vapour-compression system has four components: a
  • compressor a condenser or heat exchanger
  • thermal expansion valve also called a throttle valve
  • evaporator an evaporator
  • Circulating refrigerant enters the compressor in the thermodynamic state known as a saturated vapour and is compressed to a higher pressure, resulting in a higher temperature as well.
  • the hot, compressed vapour is then in the thermodynamic state known as a superheated vapour and it is at a temperature and pressure at which it can be condensed with either cooling water or cooling air.
  • That hot vapour is routed through a condenser or heat exchanger where it is cooled and condensed into a liquid by flowing through a coil, fins or tubes with cool water or cool air flowing across the coil, fins or tubes. This is where the circulating refrigerant rejects heat from the system and the rejected heat is carried away by either the water or the air (whichever may be the case).
  • the condensed liquid refrigerant in the thermodynamic state known as a saturated liquid, is next routed through an expansion valve where it undergoes an abrupt reduction in pressure. That pressure reduction results in the adiabatic flash evaporation of a part of the liquid refrigerant.
  • the auto-refrigeration effect of the adiabatic flash evaporation lowers the temperature of the liquid and vapour refrigerant mixture to where it is colder than the temperature of the enclosed space to be refrigerated.
  • the cold mixture is then routed through the coil or tubes in the evaporator.
  • a fan circulates the warm air in the enclosed space across the coil or tubes carrying the cold refrigerant liquid and vapour mixture. That warm air evaporates the liquid part of the cold refrigerant mixture.
  • the circulating air is cooled and thus lowers the temperature of the enclosed space to the desired temperature.
  • the evaporator is where the circulating refrigerant absorbs and removes heat which is subsequently rejected in the condenser and transferred elsewhere by the water or air used in the condenser.
  • the refrigerant vapour from the evaporator is again a saturated vapour and is routed back into the compressor.
  • a refrigeration unit such as a refrigerated beverage merchandising unit (RBMU)
  • RBMU refrigerated beverage merchandising unit
  • a refrigeration system electromechanical compressor pump, refrigerant, evaporator, heat exchanger and an expansion valve
  • a means of controlling when a compressor runs to control the temperature of a chilled beverage merchandising unit comprises a refrigeration system (electromechanical compressor pump, refrigerant, evaporator, heat exchanger and an expansion valve) fitted with a means of controlling when a compressor runs to control the temperature of a chilled
  • RBMU refrigerated beverage merchandising unit
  • Control of a compressor may be carried out in a variety of ways. At its most simple, control is via an electromechanical device, sited inside a chilled compartment, which detects the temperature and contains a contact to switch the compressor on and off. More complex electronic devices have a temperature sensor in the chilled
  • a heat exchanger is the part of a refrigeration system that expels heat gathered from the chilled compartment.
  • the heat exchanger is located outside the cooling compartment and is cooled with air drawn through it from the ambient surroundings via an electrical fan or via convection.
  • heat exchanger overheating A heat exchanger is designed to get rid of heat and is usually constructed in a way that facilitates this. There are many different designs (plate, fin and coil, static, roll) but, in essence, all have the same objective - to create a large surface area that can be used to exchange heat to a medium (air, water etc) held at a lower temperature.
  • the present invention seeks to solve this problem and thus resides in a fault diagnostic for a heat exchanger in which ambient air temperature and heat exchanger temperature are measured.
  • a heat exchanger When a heat exchanger is in operation, its temperature will rise to a steady state, usually not reaching more than around 50 Q C or around +20 Q C above the temperature of the surrounding ambient air. Once heat exchange is no longer required by the associated device (for example, the refrigeration unit has reached its desired chilled compartment temperature), operation of the heat exchanger ceases and its temperature drops to the temperature of the ambient air temperature.
  • the present invention encompasses a heat exchanger fault diagnostic method comprising:
  • a heat exchanger temperature above a certain set point say 80 or 100 degrees Centigrade, triggers an alarm in the unit and the unit is switched off to prevent overheating.
  • a certain set point say 80 or 100 degrees Centigrade
  • the unit is able to self-diagnose that the high heat exchanger temperature is due to a high ambient temperature, the machine is instructed to take additional time to cool down before restarting the heat exchange process, rather than shutting the machine down unnecessarily. In this way, the refrigeration unit is able to keep itself open for business and reduces the need for an engineer to be called out.
  • the unit may provide an alert so that the siting of the unit may be changed to allow better air flow around the heat exchanger.
  • the method further comprises initial set-up steps in which a maximum operating temperature for the heat exchanger is set and an acceptable temperature difference between the heat exchanger temperature and ambient air temperature (Delta) is set for an efficiently operating heat exchange system.
  • the heat exchanger high temperature may be set at, say, 100 degrees Centigrade and Delta is 30 degrees Centigrade.
  • an alarm may be triggered when the heat exchanger high temperature exceeds the maximum set temperature and subtraction of ambient air temperature gives a difference (Delta) of less than 30 degrees Centigrade. However, if subtraction of ambient air temperature gives a Delta reading of greater than 30 degrees Centigrade then a different alarm is sounded, an engineer is alerted and/or operation of the heat exchanger is disabled. As the heat exchanger becomes blocked with debris, for example, the heat exchanger has a reduced ability to remove heat and so the difference between ambient air temperature and the high temperature of the heat exchanger will increase.
  • operation of the heat exchanger is informed by the operation of a compressor, such as a pump, associated with the heat exchanger.
  • a microprocessor is understood to be a multipurpose, programmable device that accepts digital and/or analogue data as input, processes it according to instructions stored in its memory, and provides results as output.
  • the microprocessor is able to sense or detect whether the compressor is running or not, by way of any conventional means such as a switch, and save the temperature readings.
  • the temperature readings are saved by the microprocessor into separate files (heat exchanger temperature and ambient air temperature). The second temperature is then subtracted from the first and a diagnosis made on whether or not the heat exchanger is functioning efficiently.
  • the heat exchanger requires time to cool down after operation and so, in a preferred embodiment, the ambient air temperature around the heat exchanger is measured after a time period that is sufficient to enable the heat exchanger to cool to, or near to, ambient temperature. For example, such a time period may be approximately 2 to 5 minutes after the heat exchanger has ceased to operate.
  • the two temperatures are measured by two temperature sensors: one to measure the temperature of the heat exchanger and a second to measure the temperature of the ambient air.
  • the two temperatures are measured by a single temperature sensor.
  • the temperature sensor may be mounted on or close to the heat exchanger. Because temperature is measured and recorded over time, two sensors may be replaced by a single sensor. The difference in temperature recordings is sufficient to enable the microprocessor to determine whether or not the heat exchanger is functioning efficiently and, if not, whether there is a fault or the inefficiency is due to a high ambient air temperature.
  • the single sensor is used to assess the efficiency of the heat exchanger such that, when the difference between the two temperatures falls below a critical level, the microprocessor is able to ascertain whether the inefficiency is due to a high ambient air temperature and so keep the unit functioning, rather than raising an alarm and/or shutting down the associated refrigeration system.
  • the use of a single sensor, in place of two sensors reduces the complexity and cost in construction of devices such as refrigerator units while retaining the diagnostic capability of two separate temperature sensors.
  • Figure 1 is a scheme setting out the flow of instructions for the method and single sensor of the invention when installed in a refrigeration unit such as a RBMU; and
  • Figure 2 is a scheme setting out the flow of instructions for overheating of a heat exchanger in a refrigeration unit.
  • a refrigeration unit includes a heat exchanger and a compressor in which the compressor compresses and vaporises circulating refrigerant.
  • the unit also includes a microprocessor.
  • the microprocessor begins a two- pronged routine to enable dual sensing of heat exchanger temperature and ambient air temperature. First, the microprocessor enquires whether or not the compressor is running.
  • the microprocessor starts a High Temperature routine to ascertain the temperature of the heat exchanger. If the parameter DTS (dual temperature sensor) is equal to 1 , the dual temperature sensor is enabled on the refrigeration unit. The compressor is then confirmed to be running and the
  • HT current temperature
  • microprocessor simply instructs the recording of the heat exchange temperature because the dual temperature sensing feature is not enabled.
  • a maximum pre-set threshold for example a temperature between 50 and 125 degrees Celsius
  • the compressor is switched off.
  • the microprocessor subtracts the stored ambient air temperature from the high heat exchanger temperature. If the difference between the two temperatures is less than a programmed value (for example, 30 degrees Celsius), the high ambient temperature is flagged as a warning and the heat exchanger continues to operate after an extended period of cooling down.
  • the difference between the two temperatures is greater than the programmed value (for example, about 30 degrees Celsius)
  • this may be used to trigger an alarm or a service request for an engineer, and/or the refrigeration unit is kept switched off until a service call is answered.
  • the compressor is not running, the second part of the routine is initiated. If the parameter DTS is not equal to 1 , the dual temperature sensor is not enabled and the routine ends.
  • the dual temperature sensor is confirmed to be enabled.
  • the microprocessor then enquires whether the compressor is off. If the compressor is recorded as running, this part of the routine finishes and the temperature sensor simply records the temperature of the heat exchanger according to the first prong of the routine.
  • Rest Time is the minimum amount of time for which the compressor must be off between cycles. This is to prevent the compressor cycling too often, which results in mechanical damage. Rest Time is set within the microprocessor and is dependent on the compressor and its expected load. Rest Time starts when the compressor is switched off and a typical time for a RBMU is between 2 and 5 minutes.
  • the microprocessor instructs the temperature sensor to take a temperature reading and to write that reading to the memory of the microprocessor as ambient air temperature.
  • the ambient air temperature timer is also started.
  • the ambient air temperature timer is the additional time allowed from end of the pre- set Rest Time to enable the microprocessor to record ambient air temperature. If the refrigeration compartment in the unit reaches a temperature at which the compressor needs to be run, the refrigeration compartment will start the compressor and override the ambient air temperature timer. The temperature sensor will then revert to the high temperature sensor routine described above where the temperature of the heat exchanger is recorded.
  • the ambient air temperature reading is only stored to memory while the compressor is off and the ambient air temperature timer is running if the temperature reading is less than the previous reading stored in the microprocessor memory.
  • the previous value stored in the memory value is over-written with the new value. This is to prevent rogue spikes in temperature from being erroneously recorded, caused by residual heat in the heat exchanger.
  • the microprocessor instructs the temperature sensor to take a temperature reading. This reading is stored to the microprocessor memory and over-writes the previously stored value, regardless of whether it is higher or lower than the stored value. Ambient air temperature is thus recorded as the last temperature stored.
  • the routine returns to the beginning and enquires whether the compressor is on or off.
  • the compressor and the temperature recordings act in parallel, with the compressor being thermostat controlled and the temperature sensor recording ambient air temperature as and when the opportunity allows.
  • the temperature sensor acts as a high temperature sensor and continuously records the temperature of the heat exchanger with no rules.
  • the rules outlined above only apply when the compressor is not running and Rest Time has expired. The rules enable the microprocessor to determine the ambient air temperature around the heat exchanger from the temperature of the heat exchanger itself once the compressor and heat exchanger have not been in operation for at least the pre-set Rest Time period.

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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)
  • Air Conditioning Control Device (AREA)

Abstract

L'invention concerne un procédé de diagnostic de défaillance pour un échangeur de chaleur, consistant à mesurer la température de l'air ambiant et la température de l'échangeur de chaleur. L'invention concerne également l'utilisation d'un capteur de température unique, en combinaison avec un microprocesseur, pour mesurer la température émise à partir d'un échangeur de chaleur et la température de l'air ambiant entourant l'échangeur de chaleur.
PCT/GB2014/053524 2013-11-28 2014-11-28 Diagnostic de défaillance pour échangeur de chaleur WO2015079242A2 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CN201480063106.4A CN105745504A (zh) 2013-11-28 2014-11-28 热交换器故障诊断
GB1610452.3A GB2536161B (en) 2013-11-28 2014-11-28 Heat exchanger fault diagnostic
MX2016006929A MX2016006929A (es) 2013-11-28 2014-11-28 Diagnostico de fallos de intercambiador de calor.
BR112016011302A BR112016011302A2 (pt) 2013-11-28 2014-11-28 diagnóstico de falha de permutador térmico
EP14806371.2A EP3074706A2 (fr) 2013-11-28 2014-11-28 Diagnostic de défaillance pour échangeur de chaleur
US15/137,122 US20160238332A1 (en) 2013-11-28 2016-04-25 Heat Exchanger Fault Diagnostic

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1320977.0 2013-11-28
GBGB1320977.0A GB201320977D0 (en) 2013-11-28 2013-11-28 Heat exchanger fault diagnostic

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US15/137,122 Continuation US20160238332A1 (en) 2013-11-28 2016-04-25 Heat Exchanger Fault Diagnostic

Publications (2)

Publication Number Publication Date
WO2015079242A2 true WO2015079242A2 (fr) 2015-06-04
WO2015079242A3 WO2015079242A3 (fr) 2015-09-17

Family

ID=49979441

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2014/053524 WO2015079242A2 (fr) 2013-11-28 2014-11-28 Diagnostic de défaillance pour échangeur de chaleur

Country Status (7)

Country Link
US (1) US20160238332A1 (fr)
EP (1) EP3074706A2 (fr)
CN (1) CN105745504A (fr)
BR (1) BR112016011302A2 (fr)
GB (2) GB201320977D0 (fr)
MX (1) MX2016006929A (fr)
WO (1) WO2015079242A2 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107701294B (zh) * 2016-08-09 2019-11-22 联合汽车电子有限公司 节温器故障的诊断方法及系统
US10712033B2 (en) 2018-02-27 2020-07-14 Johnson Controls Technology Company Control of HVAC unit based on sensor status
US10569887B2 (en) 2018-03-16 2020-02-25 Hamilton Sundstrand Corporation Heat exchanger blockage detection to prevent ram air fan surge
WO2019193714A1 (fr) * 2018-04-05 2019-10-10 三菱電機株式会社 Climatiseur
CN115111791B (zh) * 2022-06-24 2024-02-09 深圳市酷凌时代科技有限公司 冷水机、冷凝器的积灰检测方法、装置及可读存储介质
CN114893936B (zh) * 2022-07-12 2022-09-16 深圳市兄弟制冰系统有限公司 制冰系统进出水控制系统与控制方法

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Also Published As

Publication number Publication date
WO2015079242A3 (fr) 2015-09-17
GB2536161B (en) 2017-08-02
GB201320977D0 (en) 2014-01-15
US20160238332A1 (en) 2016-08-18
GB2536161A (en) 2016-09-07
MX2016006929A (es) 2017-01-05
CN105745504A (zh) 2016-07-06
GB201610452D0 (en) 2016-07-27
BR112016011302A2 (pt) 2018-03-27
EP3074706A2 (fr) 2016-10-05

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