Abstract: A system and method for starting a compressor is provided. An amount of liquid refrigerant that is located in an oil sump of the compressor is determined. Using the determined amount of liquid refrigerant, a starting algorithm for the compressor is selected. The selected starting algorithm is configured to remove the determined amount of liquid refrigerant from the oil sump before the compressor reaches a preselected operating speed. The selected starting algorithm is then executed to start the compressor.

Abstract: An electrical feedthrough assembly for providing connection to components of a compressor. The electrical feedthrough assembly includes a housing having an inner surface defining a channel. A sealed wire assembly is provided in the channel. The sealed wire assembly includes a body having an outer surface defining a groove and a plurality of wires sealingly passing through the body. An o-ring fits in the groove to provide a hermetic seal between the body and the inner surface of the housing.

Abstract: A system for transmitting control signals to internal devices of a compressor is provided. The compressor includes a housing, a hermetic power terminal and a motor for powering the compressor. The system includes a frequency converter that is disposed externally of the compressor housing. The frequency converter converts a control signal to a high-frequency signal. A frequency decoder is disposed inside the compressor housing. The frequency decoder decodes and converts the high-frequency signal to a driver signal. An AC input power source provides electrical power to the motor, and power transmission lines connect the AC input power source to the hermetic power terminal. The frequency converter is electrically coupled to the frequency decoder by two power transmission lines. The frequency decoder generates a driver signal in response to the high frequency signal for operating at least one of the internal devices of the compressor.

Abstract: A pressure equalization system staffs a compressor while maintaining the condenser at a high pressure, including a valve and a bleed port. The compressor inlet receives a fluid at a first pressure. The compressor outlet discharges the fluid at a second pressure, and is operable to compress the fluid from the first pressure to the second pressure. The valve, proximate to and in fluid communication with the compressor outlet, is movable to an open position during compressor operation to permit the fluid at the second pressure to flow through the valve and is movable to a closed position when the compressor stops operating to prevent backflow of the fluid at the second pressure through the valve toward the compressor inlet. The bleed port, upstream of the valve and in fluid communication with the compressor inlet, equalizes the pressure of the fluid contained in the compressor when compressor operation stops.

Abstract: A system and method of sizing an inner diameter of the center bore of a laminated rotor is provided. The inner diameter of the center bore is determined by taking a series of measurements in the center bore with an electronic gauge and then analyzing the measurements to determine the acceptability of the rotor. The electronic gauge is inserted into the center bore of the rotor and measurements of the inner diameter of the center bore are taken at a variety of different depths and positions using the electronic gauge. The measurements are then analyzed to determine if the rotor is acceptable for use by evaluating the measurements with respect to a reference diameter and a depth in the center bore.

Abstract: A method of assembling and manufacturing a laminated rotor is provided which uses laminations having a thin bridge thickness. Different techniques are provided for preventing the molten material used in the casting or injection molding operation from leaking or seeping between the laminations during casting. In one technique, the laminations are stacked and oriented in the conventional way, and then both axial and radial pressures are applied to the stacked laminations to hold the laminations in position for the casting process. In another technique, the laminations are formed or extruded with a lip or collar portion that fit in a countersunk portion of an adjacent lamination and forms a wall or barrier between the laminations to prevent the leakage of the molten material during the casting or injection molding operation.

Abstract: A method of assembling and manufacturing a laminated rotor is provided which uses laminations having a thin bridge thickness. Different techniques are provided for preventing the molten material used in the casting or injection molding operation from leaking or seeping between the laminations during casting. In one technique, the laminations are stacked and oriented in the conventional way, and then both axial and radial pressures are applied to the stacked laminations to hold the laminations in position for the casting process. In another technique, the laminations are formed or extruded with a lip or collar portion that fit in a countersunk portion of an adjacent lamination and forms a wall or barrier between the laminations to prevent the leakage of the molten material during the casting or injection molding operation.

Abstract: A system and method of sizing an inner diameter of the center bore of a laminated rotor is provided. The inner diameter of the center bore is determined by taking a series of measurements in the center bore with an electronic gauge and then analyzing the measurements to determine the acceptability of the rotor. The electronic gauge is inserted into the center bore of the rotor and measurements of the inner diameter of the center bore are taken at a variety of different depths and positions using the electronic gauge. The measurements are then analyzed to determine if the rotor is acceptable for use by evaluating the measurements with respect to a reference diameter and a depth in the center bore.

Abstract: A method of assembling and manufacturing a laminated rotor is provided which uses laminations having a thin bridge thickness. Different techniques are provided for preventing the molten material used in the casting or injection molding operation from leaking or seeping between the laminations during casting. In one technique, the laminations are stacked and oriented in the conventional way, and then both axial and radial pressures are applied to the stacked laminations to hold the laminations in position for the casting process. In another technique, the laminations are formed or extruded with a lip or collar portion that fit in a countersunk portion of an adjacent lamination and forms a wall or barrier between the laminations to prevent the leakage of the molten material during the casting or injection molding operation.

Abstract: A system and method for controlling a variable capacity compressor driven by a motor. Preferably, said system and method are used with a reversible, two-stage compressor motor. In one embodiment, the method includes, for example, operating the variable capacity compressor at a first capacity to satisfy a demand for heating or cooling; detecting a change in the demand for heating or cooling; operating the variable capacity compressor at a second, different capacity based on the detected change in demand; detecting an operating parameter that can indicate an opportunity to increase compressor efficiency when the compressor is operating at a given capacity; and varying the torque applied by the motor when the detected operating parameter indicates an opportunity to increase efficiency of the compressor by varying the torque.

Abstract: A system and method for controlling a variable capacity compressor driven by a motor. Preferably, said system and method are used with a reversible, two-stage compressor motor. In one embodiment, the method includes, for example, operating the variable capacity compressor at a first capacity to satisfy a demand for heating or cooling; detecting a change in the demand for heating or cooling; operating the variable capacity compressor at a second, different capacity based on the detected change in demand; detecting an operating parameter that can indicate an opportunity to increase compressor efficiency when the compressor is operating at a given capacity; and varying the torque applied by the motor when the detected operating parameter indicates an opportunity to increase efficiency of the compressor by varying the torque.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: An electrical control system for an induction motor for achieving optimum efficiency at both full and partial loads at markedly reduced electrical components costs while maximizing reliability over the range of load, and for achieving a two step motor power output in a greatly simplified manner, the circuit having an electrical induction motor adapted for connection to line electrical power at maximum motor operating frequency, and to a second source of electrical power at approximately one half of the maximum operating frequency, wherein an electrical switch is provided for selectively connecting each power source to the motor, wherein the second source is a reduced frequency wave form generator for producing a reduced frequency wave form.

Abstract: A two stage reciprocating compressor and associated HVAC systems and methods are disclosed. The reciprocating compressor includes a crankshaft having an eccentric crankpin, a reversible motor for rotating the crankshaft in a forward and a reverse direction, and an eccentric, two position cam rotatably mounted over the crankpin. The crankshaft and cam combine to cause the piston to have a first stroke when the motor operates in the forward direction and a second stroke when the motor operates in the reverse direction. The cam and crankpin also include stabilization means to restrict the relative rotation of the cam about the crankpin. A lubrication system is provided to lubricate the engaging surfaces of the crankshaft and cam and between the cam and the bearing surface of the connecting rod. There is also provided a control for selectively operating the motor either in the forward direction at a first power load or in the reverse direction at a reduced second power load.

Abstract: An electrical control system for an induction motor for achieving optimum efficiency at both full and partial loads at markedly reduced electrical components costs while maximizing reliability over the range of load, and for achieving a two step motor power output in a greatly simplified manner, the circuit having an electrical induction motor adapted for connection to line electrical power at maximum motor operating frequency, and to a second source of electrical power at approximately one half of the maximum operating frequency, wherein an electrical switch is provided for selectively connecting each power source to the motor, wherein the second source is a generator for producing a reduced frequency sine wave form.