Abstract: A climate-control system may include a compressor, a condenser, an evaporator, a first sensor, a second sensor, a third sensor, and a control module. The compressor may include a motor and a compression mechanism. The condenser receives compressed working fluid from the compressor. The evaporator is in fluid communication with the compressor and disposed downstream of the condenser and upstream of the compressor. The first sensor may detect an electrical operating parameter of the motor. The second sensor may detect a discharge temperature of working fluid discharged by the compression mechanism. The third sensor may detect a suction temperature of working fluid between the evaporator and the compression mechanism. The control module is in communication with the first, second and third sensors and may determine whether a refrigerant floodback condition is occurring in the compressor based on data received from the first, second and third sensors.

Abstract: A climate-control system may include a compressor and a control module. The compressor includes a motor driving a compression mechanism to compress a working fluid. The control module is in communication with the motor and may be configured to determine a balance speed of the motor at which a forward-rotational inertial force of the compression mechanism is equal to a backward-rotational gas force on the compression mechanism. The control module may be configured to adjust a running speed of the motor to the balance speed after receipt of a compressor-shutdown-command and before shutting down the compressor.

Abstract: A system includes a plurality of compressors, an evaporator, an expansion device, and a system controller. The compressors may be linked in parallel. The system controller may: determine a saturated evaporator temperature, a saturated condensing temperature, and a target capacity demand; determine an estimated system capacity and an estimated power consumption for each compressor operating configuration; compare the estimated system capacity with the target capacity demand and an error tolerance value; select an optimum operating mode based on the comparisons and based on the estimated power consumption; and command activation and deactivation of the plurality of compressors to achieve the selected optimum operating mode. The optimum operating mode may be selected after the normal system logic achieves a steady state and may be selected from a group having the estimated system capacity within the error tolerance of the target capacity demand and a lowest associated power consumption value.

Abstract: A compressor is provided and may include a first scroll member having an end plate and a spiral wrap extending from the end plate. The end plate may include a first modulation port and a second modulation port each in fluid communication with a compression pocket formed by the spiral wrap. A first modulation valve ring may be movable relative to the end plate between a first position blocking the first modulation port and a second position spaced apart from the first modulation port. A second modulation valve ring may movable relative to the end plate between a first position blocking the second modulation port and a second position spaced apart from the second modulation port. The second modulation ring may be located radially inward from the first modulation valve ring.

Abstract: A compressor may include a non-orbiting scroll, an orbiting scroll, a driveshaft and an Oldham coupling. The orbiting scroll meshingly engages the non-orbiting scroll. The driveshaft includes a crankpin engaging the orbiting scroll and driving the orbiting scroll in an orbital path relative to the non-orbiting scroll. The Oldham coupling may include an annular body and a plurality of first keys extending from the annular body and slidably received in slots formed in the orbiting scroll. Each of the first keys may include a first post and a first cap covering at least a portion of the first post. The first posts may be integrally formed with the annular body from a first material. The first caps may be attached to the first posts and formed from a second material.

Abstract: A method of operating an electric motor is disclosed. The method includes: starting the electric motor in an open loop control mode; operating an estimator that estimates operating conditions of the electric motor; and, while the electric motor is in the open loop control mode, evaluating a first parameter of the estimator. The method further includes: in response to the evaluation of the first parameter, determining whether the estimator has converged; and in response to a determination that the estimator has not converged within a predetermined period of time after starting the electric motor, signaling a first fault condition.

Abstract: A method of operating an electric motor is disclosed. The method includes: determining a d-axis resistance of an electric motor and a Q-axis resistance of the electric motor as a function of a bulk current; determining a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current; generating an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor; generating an estimated angle of the electric motor based on the estimated flux of the electric motor; and, based on the estimated angle of the electric motor, controlling switching of an inverter that powers the electric motor.

Abstract: A climate-control system may include a variable-capacity compressor unit and a control module controlling the compressor unit. The compressor unit may be operable in a first capacity mode and in a second capacity mode that is higher than the first capacity mode. The control module may be configured to switch the compressor unit among a shutdown state, the first capacity mode and the second capacity mode based on a demand signal and outdoor-air-temperature data.

Abstract: A system may include a compressor including a compression mechanism having first and second compression members defining a compression pocket disposed between the first and second compression members that decreases in volume during operation of the compression mechanism. A heat exchanger receives compressed working fluid from the compressor. An expansion device may be disposed downstream of the heat exchanger. A lubricant separator receives lubricant and working fluid discharged from the compression mechanism and provides separated lubricant to the compression mechanism. A lubricant-injection flow path may include a lubricant fitting and extends between the lubricant separator and the compression pocket such that separated lubricant is injected into the compression pocket through the lubricant fitting.

Abstract: A control system for a motor in a refrigeration system includes an angle determination module configured to generate an output rotor angle indicative of a desired angle of a rotor of the motor. The control system controls current supplied to the motor based on the output rotor angle. The control system determines an estimated rotor angle of the motor. The angle determination module, upon startup of the motor, generates the output rotor angle based on a first rotor angle. Upon generation of a transition signal, the angle determination module generates the output rotor angle based on both the first rotor angle and the estimated rotor angle. Subsequent to generation of the transition signal, the angle determination module reduces a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

Abstract: A compressor is provided and may include a shell, an orbiting scroll, a driveshaft and an unloader counterweight. The orbiting scroll may be disposed within the shell and include a boss portion. The driveshaft may include an eccentric pin and rotate about a longitudinal axis. The unloader counterweight assembly may include a first, a second end, and a longitudinal opening extending therebetween. The eccentric pin of the driveshaft may be disposed within the longitudinal opening at the first end of the unloader counterweight assembly. The boss portion of the orbiting scroll may be disposed within the longitudinal opening at the second end of the unloader counterweight assembly.

Abstract: A light-weight, high-strength compressor component having at least one fluid delivery feature that is formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure has at least one fluid delivery feature for permitting fluid flow through the body portion of the light-weight, high-strength compressor component. The fluid delivery feature may be a flow channel, a fluid delivery port, a porous fluid delivery feature, or the like that serves to transfer fluids through the component, such as refrigerant and/or lubricant oils. Methods of making such compressor components via additive manufacturing processes are also provided.

Abstract: A light-weight, high-strength compressor component is formed via additive manufacturing that has controlled stiffness and/or deflection levels. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprises the lattice structure in the body portion of the light-weight, high-strength compressor component. The lattice structure may be used to globally or locally control stiffness and/or deflection levels of the compressor component. Additive manufacturing provides flexibility in forming compressor components with desirably improved strength-to-weight ratios while exhibiting high levels of control over stiffness and/or deflection. Methods of making such compressor components via additive manufacturing processes are also provided.

Abstract: A light-weight, high-strength insulating compressor component formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure minimizes or reduces transmission of at least one of thermal energy, sound, or vibrational energy through the component. Methods of making such compressor components via additive manufacturing processes are also provided.

Abstract: A monitoring system is disclosed for a heating, ventilation, or air conditioning (HVAC) system of a residential or commercial building. The monitoring system includes an evaporator unit device including a first current sensor that measures current supplied to a circulator blower. The measured current from the first current sensor is used to diagnose a problem with the circulator blower. The monitoring system includes a first temperature sensor that measures refrigerant temperature between a condenser and an expansion valve. The monitoring system includes a second temperature sensor that measures refrigerant temperature between an evaporator and a compressor. The monitoring system includes a condenser unit device that communicates with the evaporator unit device. The condenser unit device includes a second current sensor that measures current supplied to the compressor. The evaporator unit device transmits sensor data to a remote monitoring service over a data network.

Abstract: Scroll compressor designs are provided to minimize vibration, sound, and noise transmission. The scroll compressor has a bearing housing, and orbiting and non-orbiting scroll members. The non-orbiting scroll member has a radially extending flanged portion with at least one aperture substantially aligned with the axially extending bore. At least one fastener is disposed within the aperture and the bore. A sound isolation member contacts at least one of the non-orbiting scroll member, the fastener, or the bearing housing, to reduce or eliminate noise transmission. The sound isolation member may be formed of a polymeric composite having an acoustic impedance value greater than the surrounding materials. The sound isolation member may be an annular washer, an O-ring, or a biasing member, by way of non-limiting example. In other variations, fluid passages are provided within the fastener and/or bearing housing to facilitate entry of lubricant oil to further dampen sound and noise.

Abstract: An ice machine may include a compressor, a first heat exchanger, an expansion device, an evaporator, an ice tray, and a water pump. The first heat exchanger may receive compressed working fluid from the compressor. The expansion device may receive working fluid from the first heat exchanger. The evaporator may receive working fluid from the expansion device. The ice tray may be in a heat transfer relationship with the evaporator. The ice tray may include a plurality of ice molds. The water pump may be in fluid communication with the ice molds and may be configured to pump water from a water source to the ice molds.

Abstract: A system and method are provided for a variable speed compressor with a control module that controls an operating frequency of the variable speed compressor. The control module stores a prohibited frequency range that includes a resonant frequency of the variable speed compressor and an allowed upper frequency above the prohibited frequency range and an allowed lower frequency below the prohibited frequency range. The control module determines a requested frequency and operates the variable speed compressor at the allowed upper frequency for an upper frequency operating time and at the allowed lower frequency for a lower frequency operating time when the requested frequency is within the prohibited frequency range. The control module determines the upper frequency operating time and the lower frequency operating time such that a time-averaged frequency output over the upper frequency operating time and the lower frequency operating time corresponds to the requested frequency.

Abstract: A method is provided that includes installing a compressor in a refrigeration system and determining a condenser temperature difference using processing circuitry. The method also includes checking for an overcharge condition or a condenser fan blockage condition when the condenser temperature difference is greater than a high condenser temperature difference value. The method also includes determining a discharge superheat temperature using the processing circuitry and checking for the overcharge condition or the condenser fan blockage condition when the condenser temperature difference is less than the high condenser temperature difference value and the discharge superheat temperature is less than a low discharge superheat temperature value.

Abstract: A system may include first and second compressors, first and second heat exchangers, a flash tank, and first, second and third fluid paths. The first compressor may include first and second inlets. The second compressor may receive fluid from an outlet of the first compressor. The first heat exchanger may receive fluid from the second compressor. The flash tank may receive fluid from the first heat exchanger and includes a vapor outlet and a liquid outlet. The second heat exchanger may be in fluid communication with the flash tank and may receive fluid from the liquid outlet. The first fluid path extends from an outlet of the second heat exchanger to an inlet of the second compressor. The second fluid path extends from the vapor outlet to the first fluid path. The third fluid path may transmit fluid from the vapor outlet to the second inlet.