COMPRESSOR DATA MODULE

Abstract

A compressor includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a processor and a memory. The compressor controller includes a processor and a memory. The data module receives sensed data, stores sensed data in the memory, and communicates sensed data to the compressor controller. The compressor controller controls a capacity of the compressor based on the sensed data and is operable to communicate with a system controller of a refrigeration system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/842,898, filed on Sep. 7, 2006. The disclosure of the above application is incorporated herein by reference.

FIELD

The present disclosure relates to compressors, and more particularly, to a data module for use with a compressor.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Compressors are used in a wide variety of industrial and residential applications to circulate refrigerant within a refrigeration, heat pump, HVAC, or chiller system (generically referred to as “refrigeration systems”) to provide a desired heating and/or cooling effect. In any of the foregoing applications, the compressor should provide consistent and efficient operation to ensure that the particular refrigeration system functions properly.

Refrigeration systems and associated compressors may include a protection device that intermittently restricts power to the compressor to prevent operation of the compressor and associated components of the refrigeration system (i.e., evaporator, condenser, etc.) when conditions are unfavorable. For example, when a particular fault or failure is detected within the compressor, the protection device may restrict power to the compressor to prevent operation of the compressor and refrigeration system under such conditions.

The types of faults that may cause protection concerns include electrical, mechanical, and system faults. Electrical faults typically have a direct effect on an electrical motor associated with the compressor, while mechanical faults generally include faulty bearings or broken parts. Mechanical faults often raise a temperature of working components within the compressor and, thus, may cause malfunction of, and possible damage to, the compressor.

In addition to electrical and mechanical faults associated with the compressor, the refrigeration system components may be affected by system faults attributed to system conditions such as an adverse level of fluid disposed within the system or to a blocked-flow condition external to the compressor. Such system conditions may raise an internal compressor temperature or pressure to high levels, thereby damaging the compressor and causing system inefficiencies and/or failures. To prevent system and compressor damage or failure, the compressor may be shut down by the protection system when any of the aforementioned conditions are present.

Conventional protection systems may sense temperature and/or pressure parameters as discrete switches to interrupt power supplied to the electrical motor of the compressor should a predetermined temperature or pressure threshold be exceeded. Such systems typically employ multiple temperature and pressure sensors to detect operating parameters of the compressor, which results in a complex and costly protection system.

Because conventional protection systems directly control a compressor to which they are tied, conventional protection systems cannot be used with multiple control modules, and may only be used with a single compressor and a single controller.

SUMMARY

A compressor includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a processor and a memory. The compressor controller includes a processor and a memory. The data module receives sensed data, stores sensed data in the memory, and communicates sensed data to the compressor controller. The compressor controller controls a capacity of the compressor based on the sensed data and is operable to communicate with a system controller of a refrigeration system.

In a refrigeration system that includes a system controller in communication with a compressor controller associated with a compressor, a data module includes a housing, a processor and a memory. The housing is mountable on the compressor and the processor receives sensed data, stores sensed data in the memory, and is operable to communicate sensed data to the compressor controller.

A compressor control system includes a compressor and a compressor controller that is operable to diagnose and/or control the compressor. A data module is associated with the compressor, is in communication with the compressor controller, and receives sensor data indicative of compressor performance. It further determines non-measured system operating parameters and diagnoses the compressor based on at least one of the sensor data and the non-measured system operating parameters. The data module further communicates the sensor data, the non-measured system operating parameters, and the diagnosis to the compressor controller.

A method includes communicating sensor data to a data module, processing the sensor data at the data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system, and processing at least one of the sensor data and the determined non-measured operating parameters at the data module to diagnose the at least one compressor and refrigeration system. A method further includes communicating the sensor data, the non-measured operating parameters, and the diagnosis to a system controller. The non-measured operating parameters are determined at the system controller based on the received sensor data and the diagnosis at the system controller is determined based on the received sensor data and the non-measured operating parameters. The received non-measured operating parameters are compared to the determined non-measured operating parameters at the system controller and the received diagnosis is compared to the determined diagnosis at the system controller.

A method further includes communicating sensor data to a data module and processing the sensor data at the data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system. At least one of the sensor data and the non-measured operating parameters are processed at the data module to diagnose the at least one compressor and refrigeration system. At least one of the sensor data, the non-measured operating parameters, and the diagnosis is stored in a memory of the data module. At least one of the sensor data, the non-measured operating parameters, and the diagnosis is communicated to a first system controller. The first system controller is replaced with a second system controller. At least one of the stored sensor data, the stored non-measured operating parameters, and the stored diagnosis is communicated to the second controller.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

FIG. 1 is a perspective view of a compressor incorporating a data module in accordance with the principles of the present teachings;

FIG. 2 is a cross-sectional view of the compressor of FIG. 1;

FIG. 3 is a schematic representation of a refrigeration system incorporating the compressor of FIG. 1;

FIG. 4 is a table illustrating various sensor combinations used to determine various compressor and system operating parameters;

FIG. 5 is a graph of compressor current versus condenser temperature for use in determining condenser temperature at a given evaporator temperature;

FIG. 6 is a graph of discharge temperature versus evaporator temperature for use in determining an evaporator temperature at a given condenser temperature;

FIG. 7 is a graph of discharge superheat versus suction superheat to determine suction superheat at a given outdoor/ambient temperature;

FIG. 8 is a schematic representation of the data module of FIG. 1 shown in communication with a diagnostic and control module and a plurality of sensors;

FIG. 9 is a more detailed schematic representation of the data module of FIG. 1; and

FIG. 10 is a schematic representation of another data module for use with the compressor of FIG. 1 incorporating a diagnostic and control module and in communication with a plurality of sensors.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that proved the described functionality.

With reference to the drawings, a compressor 10 is shown incorporating a protection and control system 12. The protection and control system 12 utilizes a series of sensors and non-measured operating parameters derived from information received from the sensors to diagnose the compressor 10 and refrigeration system 11 to which the compressor 10 may be tied. The protection and control system 12 includes a data module 14 and a diagnostics and control module 15. The data module 14 may provide multiple levels of data for use by the diagnostics and control module 15 in diagnosing and controlling the compressor 10 and/or refrigeration system 11. For example, the data module 14 may provide three levels of data for use by the diagnostics and control module 15, including sensor data, non-measured operating parameters (i.e., processed sensor data), and diagnostics for use by the diagnostics and control module 15 in diagnosing and controlling the compressor 10 and/or refrigeration system 11.

The data provided by the data module 14 is not controller specific. Therefore, the data module 14 may be used with any control module. Providing the data module 14 with the ability to be used with any control module allows the data module 14 flexibility in that the data module 14 may be used with various controllers of various manufacturers and configurations.

With particular reference to FIGS. 1 and 2, the compressor 10 is shown to include a generally cylindrical hermetic shell 17 having a welded cap 16 at a top portion and a base 18 having a plurality of feet 20 welded at a bottom portion. The cap 16 and the base 18 are fitted to the shell 17 such that an interior volume 22 of the compressor 10 is defined. The cap 16 is provided with a discharge fitting 24, while the shell 17 is similarly provided with an inlet fitting 26, disposed generally between the cap 16 and base 18, as best shown in FIG. 2. In addition, an electrical enclosure 28 is fixedly attached to the shell 17 generally between the cap 16 and the base 18 and supports a portion of the protection and control system 12 therein.

A crankshaft 30 is rotatably driven by an electric motor 32 relative to the shell 17. The motor 32 includes a stator 34 fixedly supported by the hermetic shell 17, windings 36 passing therethrough, and a rotor 38 press-fit on the crankshaft 30. The motor 32 and associated stator 34, windings 36, and rotor 38 cooperate to drive the crankshaft 30 relative to the shell 17 to compress a fluid.

The compressor 10 further includes an orbiting scroll member 40 having a spiral vein or wrap 42 on an upper surface thereof for use in receiving and compressing a fluid. An Oldham coupling 44 is disposed generally between the orbiting scroll member 40 and bearing housing 46 and is keyed to the orbiting scroll member 40 and a non-orbiting scroll member 48. The Oldham coupling 44 transmits rotational forces from the crankshaft 30 to the orbiting scroll member 40 to compress a fluid disposed generally between the orbiting scroll member 40 and the non-orbiting scroll member 48. Oldham coupling 44, and its interaction with orbiting scroll member 40 and non-orbiting scroll member 48, is preferably of the type disclosed in assignee's commonly owned U.S. Pat. No. 5,320,506, the disclosure of which is incorporated herein by reference.

Non-orbiting scroll member 48 also includes a wrap 50 positioned in meshing engagement with the wrap 42 of the orbiting scroll member 40. Non-orbiting scroll member 48 has a centrally disposed discharge passage 52, which communicates with an upwardly open recess 54. Recess 54 is in fluid communication with the discharge fitting 24 defined by the cap 16 and a partition 56, such that compressed fluid exits the shell 17 via discharge passage 52, recess 54, and fitting 24. Non-orbiting scroll member 48 is designed to be mounted to bearing housing 46 in a suitable manner such as disclosed in assignee's commonly owned U.S. Pat. Nos. 4,877,382 and 5,102,316, the disclosures of which are incorporated herein by reference.

The electrical enclosure 28 includes a lower housing 58, an upper housing 60, and a cavity 62. The lower housing 58 is mounted to the shell 17 using a plurality of studs 64, which are welded or otherwise fixedly attached to the shell 17. The upper housing 60 is matingly received by the lower housing 58 and defines the cavity 62 therebetween. The cavity 62 is positioned on the shell 17 of the compressor 10 and may be used to house respective components of the protection and control system 12 and/or other hardware used to control operation of the compressor 10 and/or refrigeration system 11.

With particular reference to FIG. 2, the compressor 10 includes an actuation assembly 65 that selectively separates the orbiting scroll member 40 from the non-orbiting scroll member 48 to modulate a capacity of the compressor 10. The actuation assembly 65 may include a solenoid 66 connected to the orbiting scroll member 40 and a controller 68 coupled to the solenoid 66 for controlling movement of the solenoid 66 between an extended position and a retracted position.

Movement of the solenoid 66 into the extended position separates the wraps 42 of the orbiting scroll member 40 from the wraps 50 of the non-orbiting scroll member 48 to reduce an output of the compressor 10. Conversely, movement of the solenoid 66 into the retracted position moves the wraps 42 of the orbiting scroll member 40 closer to the wraps 50 of the non-orbiting scroll member 48 to increase an output of the compressor. In this manner, the capacity of the compressor 10 may be modulated in accordance with demand or in response to a fault condition.

While movement of the solenoid 66 into the extended position is described as separating the wraps 42 of the orbiting scroll member 40 from the wraps 50 of the non-orbiting scroll member 48, movement of the solenoid 66 into the extended position could alternately move the wraps 42 of the orbiting scroll member 40 into engagement with the wraps 50 of the non-orbiting scroll member 48. Similarly, while movement of the solenoid 66 into the retracted position is described as moving the wraps 42 of the orbiting scroll member 40 closer to the wraps 50 of the non-orbiting scroll member 48, movement of the solenoid 66 into the retracted position could alternately move the wraps 42 of the orbiting scroll member 40 away from the wraps 50 of the non-orbiting scroll member 48. The actuation assembly 65 is preferably of the type disclosed in assignee's commonly owned U.S. Pat. No. 6,412,293, the disclosure of which is incorporated herein by reference.

With particular reference to FIG. 3, the refrigeration system 11 includes a condenser 70, an evaporator 72, and an expansion device 74 disposed generally between the condenser 70 and the evaporator 72. The refrigeration system 11 also includes a condenser fan 76 associated with the condenser 70 and an evaporator fan 78 associated with the evaporator 72. Each of the condenser fan 76 and the evaporator fan 78 may be variable-speed fans that can be controlled based on a cooling and/or heating demand of the refrigeration system 11. Furthermore, each of the condenser fan 76 and evaporator fan 78 may be controlled by the protection and control system 12 such that operation of the condenser fan 76 and evaporator fan 78 may be coordinated with operation of the compressor 10.

In operation, the compressor 10 circulates refrigerant generally between the condenser 70 and evaporator 72 to produce a desired heating and/or cooling effect. The compressor 10 receives vapor refrigerant from the evaporator 72 generally at the inlet fitting 26 and compresses the vapor refrigerant between the orbiting scroll member 40 and the non-orbiting scroll member 48 to deliver vapor refrigerant at discharge pressure at discharge fitting 24.

Once the compressor 10 has sufficiently compressed the vapor refrigerant to discharge pressure, the discharge-pressure refrigerant exits the compressor 10 at the discharge fitting 24 and travels within the refrigeration system 11 to the condenser 70. Once the vapor enters the condenser 70, the refrigerant changes phase from a vapor to a liquid, thereby rejecting heat. The rejected heat is removed from the condenser 70 through circulation of air through the condenser 70 by the condenser fan 76. When the refrigerant has sufficiently changed phase from a vapor to a liquid, the refrigerant exits the condenser 70 and travels within the refrigeration system 11 generally towards the expansion device 74 and evaporator 72.

Upon exiting the condenser 70, the refrigerant first encounters the expansion device 74. Once the expansion device 74 has sufficiently expanded the liquid refrigerant, the liquid refrigerant enters the evaporator 72 to change phase from a liquid to a vapor. Once disposed within the evaporator 72, the liquid refrigerant absorbs heat, thereby changing from a liquid to a vapor and producing a cooling effect. If the evaporator 72 is disposed within an interior of a building, the desired cooling effect is circulated into the building to cool the building by the evaporator fan 78. if the evaporator 72 is associated with a heat-pump refrigeration system, the evaporator 72 may be located remote from the building such that the cooling effect is lost to the atmosphere and the rejected heat experienced by the condenser 70 is directed to the interior of the building to heat the building. In either configuration, once the refrigerant has sufficiently changed phase from a liquid to a vapor, the vaporized refrigerant is received by the inlet fitting 26 of the compressor 10 to begin the cycle anew.

With particular reference to FIGS. 2 and 3, the protection and control system 12 is shown to include a current sensor 80, a temperature sensor 82, a liquid line temperature sensor 84, and an outdoor/ambient temperature sensor 86. The protection and control system 12 also includes processing circuitry 88, 89, respectively associated with the data module 14 and diagnostics and control module 15, and a power interruption system 90. The processing circuitry 88, 89 and power interruption system 90 may be disposed within the electrical enclosure 28 mounted to the shell 17 of the compressor 10 (FIG. 2). The sensors 80, 82, 84, 86 cooperate to provide the processing circuitry 88 of the data module 14 with sensor data indicative of compressor and/or refrigeration system operating parameters for use by the processing circuitry 88 in determining operating parameters of the compressor 10 and/or refrigeration system 11 that are not directly sensed by a sensor (hereinafter “non-measured operating parameters”). The processing circuitry 88 may use the sensor data to compute the non-measured operating parameters.

The processing circuitry 88 may use the sensor data and/or non-measured operating parameters to diagnose the compressor 10 and/or refrigeration system 11. The data module 14 may transmit the sensor data, derived non-measured operating parameters, and/or compressor/refrigeration system diagnosis to the processing circuitry 89 of the diagnostics and control module 15 for use by the processing circuitry 89 in diagnosing and controlling the compressor 10 and/or refrigeration system 11. Because the data module 14 provides compressor and/or refrigeration system operational data, the data module 14 is not controller specific and may be used with various control modules including diagnostics and control module 15. Operation of the data module 14 and diagnostics and control module 15 will be described in detail below.

The current sensor 80 may provide diagnostics related to high-side faults such as compressor mechanical failures, motor failures, and electrical component failures such as missing phase, reverse phase, motor winding current imbalance, open circuit, low voltage, locked rotor current, excessive motor winding temperature, welded or open contactors, and short cycling. The current sensor 80 may monitor compressor current and voltage for use in determining and differentiating between mechanical failures, motor failures, and electrical component failures.

The current sensor 80 may be mounted within the electrical enclosure 28 or may alternatively be incorporated inside the shell 17 of the compressor 10 (FIG. 2). In either case, the current sensor 80 may monitor current drawn by the compressor 10 and generate a signal indicative thereof, such as disclosed in assignee's commonly owned U.S. Pat. No. 6,615,594, U.S. patent application Ser. No. 11/027,757 filed on Dec. 30, 2004, and U.S. patent application Ser. No. 11/059,646 filed on Feb. 16, 2005, the disclosures of which are incorporated herein by reference.

While a current sensor 80 is disclosed, the protection and control system 12 may also include a discharge-pressure sensor 92 mounted in a discharge-pressure zone and/or a temperature sensor 94 mounted within or near the compressor shell 17 such as within the discharge fitting 24 (FIG. 2) or in an external system such as the condenser 70 (FIG. 3). The temperature sensor 94 may additionally or alternatively be positioned external of the compressor 10 along a conduit 103 extending generally between the compressor 10 and the condenser 70 (FIG. 3) and may be disposed in close proximity to an inlet of the condenser 70. Any or all of the foregoing sensors may be used in conjunction with the current sensor 80 to provide the protection and control system 12 with additional system information.

The temperature sensor 82 generally provides data related to low-side faults such as a low charge in the refrigerant, a plugged orifice, an evaporator fan failure, or a leak in the compressor 10. The temperature sensor 82 may be disposed proximate to the discharge fitting 24 or the discharge passage 52 of the compressor 10 and may monitor a discharge line temperature of a compressed fluid exiting the compressor 10. In addition to the foregoing, the temperature sensor 82 may be disposed external from the compressor shell 17 and proximate to the discharge fitting 24 such that vapor at discharge pressure encounters the temperature sensor 82. Locating the temperature sensor 82 external of the shell 17 allows flexibility in compressor and system design by providing the temperature sensor 82 with the ability to be readily adapted for use with practically any compressor and any system.

While the temperature sensor 82 may provide discharge line temperature information, the protection and control system 12 may also include a suction-pressure sensor 96 or a low-side temperature sensor 98, which may be mounted proximate to an inlet of the compressor 10. In one configuration, the suction pressure sensor 96 or the low-side temperature sensor 98 is located proximate to the inlet fitting 26 (FIG. 2) or is mounted in an external system such as the evaporator 72 (FIG. 3). The suction-pressure sensor 96 and low-side temperature sensor 98 may additionally or alternatively be disposed along a conduit 105 extending generally between the evaporator 72 and the compressor 10 (FIG. 3) and may be disposed in close proximity to an outlet of the evaporator 72. Any or all of the foregoing sensors may be used in conjunction with the temperature sensor 82 to provide the protection and control system 12 with additional system information.

While the temperature sensor 82 may be positioned external to the shell 17 of the compressor 10, the discharge temperature of the compressor 10 can similarly be measured within the shell 17 of the compressor 10. A discharge-core temperature, taken generally at the discharge fitting 24, could be used in place of the discharge line temperature arrangement shown in FIG. 2. A hermetic terminal assembly 100 may be used with such an internal discharge temperature sensor to maintain the sealed nature of the compressor shell 17.

The liquid line temperature sensor 84 may be positioned either within the condenser 70 or may be positioned along a conduit 102 extending generally between an outlet of the condenser 70 and the expansion device 74. In this position, the temperature sensor 84 is located in a position within the refrigeration system 11 that represents a liquid location that is common to both a cooling mode and a heating mode if the refrigeration system 11 is a heat pump. Because the liquid line temperature sensor 84 is disposed generally near an outlet of the condenser 70 or along the conduit 102 extending generally between the outlet of the condenser 70 and the expansion device 74, the liquid line temperature sensor 84 encounters liquid refrigerant (i.e., after the refrigerant has changed from a vapor to a liquid within the condenser 70) and therefore can provide an indication of a temperature of the liquid refrigerant to the processing circuitry 88. While the liquid line temperature sensor 84 is described as being near an outlet of the condenser 70 or along a conduit 102 extending between the condenser 70 and the expansion device 74, the liquid line temperature sensor 84 may also be placed anywhere within the refrigeration system 11 that would allow the liquid line temperature sensor 84 to provide an indication of a temperature of liquid refrigerant within the refrigeration system 11 to the processing circuitry 88.

The outdoor/ambient temperature sensor 86 may be located external from the compressor shell 17 and generally provides an indication of the outdoor/ambient temperature surrounding the compressor 10 and/or refrigeration system 11. The outdoor/ambient temperature sensor 86 may be positioned adjacent to the compressor shell 17 such that the outdoor/ambient temperature sensor 86 is in close proximity to the processing circuitry 88 (FIGS. 2 and 3). Placing the outdoor/ambient temperature sensor 86 in close proximity to the compressor shell 17 provides the processing circuitry 88 of the data module 14 with a measure of the temperature generally adjacent to the compressor 10. Locating the outdoor/ambient temperature sensor 86 in close proximity to the compressor shell 17 not only provides the processing circuitry 88 with an accurate measure of the surrounding air around the compressor 10, but also allows the outdoor/ambient temperature sensor 86 to be attached to or disposed within the electrical enclosure 28.

The processing circuitry 88 of the data module 14 may receive sensor information from the current sensor 80, temperature sensor 82, liquid line temperature sensor 84, and outdoor/ambient temperature sensor 86. As shown in FIG. 4, the processing circuitry 88 uses the sensor data from the respective sensors 80, 82, 84, 86 to determine non-measured operating parameters of the compressor 10 and/or refrigeration system 11.

The processing circuitry 88 may be able to determine non-measured operating parameters of the compressor 10 and/or refrigeration system 11 based on sensor data received from the respective sensors 80, 82, 84, 86 without requiring individual sensors for each of the non-measured operating parameters. The processing circuitry 88 may be able to determine condenser temperature (T_cond), subcooling of the refrigeration system 11, a temperature difference between the condenser temperature and outdoor/ambient temperature condenser (TD), and a discharge superheat of the refrigeration system 11.

The processing circuitry 88 may determine the condenser temperature by referencing compressor power on a compressor map. The derived condenser temperature is generally the saturated condenser temperature equivalent to the discharge pressure for a particular refrigerant. The condenser temperature should be close to a temperature at a mid-point of the condenser 70. Using a compressor map to determine the condenser temperature provides a more accurate representation of the overall temperature of the condenser 70 when compared to a condenser temperature value provided by a temperature sensor mounted on a coil of the condenser 70, as the condenser coil likely includes many parallel circuits having different temperatures.

FIG. 5 is an example of a compressor map showing compressor current versus condenser temperature at various evaporator temperatures (T_evap). As shown, current remains fairly constant irrespective of evaporator temperature. Therefore, while an exact evaporator temperature can be determined by a second degree polynomial (i.e., a quadratic function), for purposes of control, the evaporator temperature can be determined by a first degree polynomial (i.e., a linear function) and can be approximated as roughly 45, 50, or 55 degrees Fahrenheit. The error associated with choosing an incorrect evaporator temperature is minimal when determining the condenser temperature. While compressor current is shown, compressor power and/or voltage may be used in place of current for use in determining condenser temperature. Compressor power may be determined based on the current drawn by motor 32, as indicated by the current sensor 80.

Once the compressor current is known it may adjust for voltage based on a baseline voltage contained in a compressor map. The condenser temperature may be determined by comparing compressor current with condenser temperature using the graph shown in FIG. 5. The above process for determining the condenser temperature is described in assignee's commonly-owned U.S. patent application Ser. No. 11/059,646 filed on Feb. 16, 2005, the disclosure of which is herein incorporated by reference.

Once the condenser temperature is known, the processing circuitry 88 may then determine the subcooling of the refrigeration system 11 by subtracting the liquid line temperature indicated by the liquid line temperature sensor 84 from the condenser temperature and then subtracting an additional small value (typically 2-3° F.) representing the pressure drop between an outlet of the compressor 10 and an outlet of the condenser 70. The processing circuitry 88 is therefore able to determine not only the condenser temperature but also the subcooling of the refrigeration system 11 without requiring an additional temperature sensor for either operating parameter.

The processing circuitry 88 may also be able to calculate a temperature difference (TD) between the condenser 70 and the outdoor/ambient temperature surrounding the refrigeration system 11. The processing circuitry 88 may determine the condenser temperature by referencing either the power or current drawn by the compressor 10 against the graph shown in FIG. 5 without requiring a temperature sensor to be positioned within the condenser 70. Once the condenser temperature is known (i.e., derived), the processing circuitry 88 can determine the temperature difference (TD) by subtracting the ambient temperature as received from the outdoor/ambient temperature sensor 86 from the derived condenser temperature.

The discharge superheat of the refrigeration system 11 may also be determined once the condenser temperature is known. Specifically, the processing circuitry 88 may determine the discharge superheat of the refrigeration system 11 by subtracting the condenser temperature from the discharge line temperature. As described above, the discharge line temperature may be detected by the temperature sensor 82 and is provided to the processing circuitry 88. Because the processing circuitry 88 can determine the condenser temperature by referencing the compressor power against the graph shown in FIG. 5, and because the processing circuitry 88 knows the discharge line temperature based on information received from the temperature sensor 82, the processing circuitry 88 can determine the discharge superheat of the compressor 10 by subtracting the condenser temperature from the discharge line temperature.

Once the discharge superheat is determined, the processing circuitry 88 can determine the suction superheat by referencing a plot as shown in FIG. 7. Specifically, the suction superheat may be determined by referencing the discharge superheat against the ambient temperature as indicated by the outdoor/ambient temperature sensor 86.

Once the condenser temperature is determined, the processing circuitry 88 can reference a plot as shown in FIG. 6 to determine the exact evaporator temperature based on discharge temperature information received from the temperature sensor 82. Once both the condenser temperature and the evaporator temperature are known, the processing circuitry 88 can then determine compressor capacity and flow.

In addition to deriving the condenser temperature, evaporator temperature, subcooling, discharge superheat, compressor capacity and flow, and suction superheat, the processing circuitry 88 may also measure or estimate the fan power of the condenser fan 76 and/or evaporator fan 78 and derive a compressor power factor for use in determining the efficiency of the refrigeration system 11 and the capacity of the evaporator 72. The fan power of the condenser fan 76 and/or evaporator fan 78 may be directly measured by sensors 85 associated with the fans 76, 78 or may be estimated by the processing circuitry 88.

Once the non-measured operating parameters are determined, the performance of the compressor 10 and refrigeration system 11 can be determined by the data module 14. As noted above, the data module 14 may provide three levels of data to the diagnostics and control module 15. First, sensor data may be transmitted from the data module 14 to the diagnostics and control module 15 for use by the diagnostics and control module 15 in diagnosing and controlling the compressor 10 and refrigeration system 11. Second, the sensor data and/or non-measured operating parameters may be transmitted to the diagnostics and control system 15 for use by the diagnostics and control module 15 in diagnosing and controlling the compressor 10 and/or refrigeration system 11. Third, the sensor data, non-measured operating parameters, and compressor/refrigeration system diagnostics may be transmitted to the diagnostics and control module 15 for use by the diagnostics and control module 15 in diagnosing and controlling the compressor 10 and/or refrigeration system 11.

The data module 14 may include configuration data and fault history data stored therein in addition to the three tiers of data discussed above. Configuration data may include compressor serial number, manufacturing date, compressor performance maps, etc., while fault history data may include a list of faults previously experienced by the compressor and/or refrigeration system and a related cause of the particular fault. The configuration data and fault history data may be provided to the diagnostics and control module 15 to update the diagnostics and control module 15 or to configure a new diagnostics and control module 15 should the diagnostics and control module 15 require replacement. For example, if the diagnostics and control module 15 becomes faulty and a new diagnostics and control module 15 is installed, the data module 14 may provide the configuration and/or fault history data to the new diagnostics and control module 15 to configure the diagnostics and control module 15. Such configuration and fault history data may include data described in assignee's commonly-owned U.S. Provisional Patent Application No. 60/674,781 filed on Apr. 26, 2005 now U.S. patent application Ser. No. 11/405,021 filed on Apr. 14, 2006, the disclosures of which are herein incorporated by reference.

With particular reference to FIGS. 8 and 9, operation of the data module 14 and diagnostics and control module 15 will be described in detail. As shown in FIG. 8, the data module 14 receives inputs from the various sensors 80, 82, 84, 86, which provide the data module 14 with current operating conditions of the compressor 10 and/or refrigeration system 11. The processing circuitry 88 of the data module 14 may use the data from the respective sensors 80, 82, 84, 86 to determine non-measured operating parameters of the compressor 10 and/or refrigeration system 11.

As described above, the data module 14 may determine non-measured operating parameters of the compressor 10 and/or refrigeration system 11 such as subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature. For example, the data module 14 may receive liquid line temperature information from the liquid line temperature sensor 84 and current and/or voltage information from the current sensor 80 and may use the information received from the respective sensors 80, 84 to determine the condenser temperature and subcooling (FIG. 4). Specifically, once the current drawn by the motor 32 is known by information received from current sensor 80, the processing circuitry 88 of data module 14 may reference the current reading from the current sensor 80 against a compressor map such as the plot shown in FIG. 5, which may be stored within the data module 14. Referencing the current drawn by the motor 32 against a compressor map such as the plot shown in FIG. 5, yields an approximated condenser temperature by referencing the current drawn by the motor 32 against an approximated evaporator temperature. Once the condenser temperature is determined by the processing circuitry 88, the subcooling may then be determined simply by subtracting the liquid line temperature as measured by the liquid line temperature sensor 84 from the determined condenser temperature, as indicated in FIG. 4.

Once the processing circuitry 88 of the data module 14 has determined the non-measured parameters of the compressor 10 and/or refrigeration system 11, the data module 14 may then transmit one or both of the sensor data received from sensors 80, 82, 84, 86 and the derived, non-measured parameters to the diagnostics and control module 15. The processing circuitry 89 of the diagnostics and control module 15 may use the sensor data from the sensors 80, 82, 84, 86 and/or the derived, non-measured parameters to diagnose the compressor 10 and/or refrigeration system 11.

Such diagnostics may be used to differentiate between various fault conditions of the compressor 10 and/or refrigeration system 11 and may be used to control/protect the compressor 10 and/or refrigeration system 11. For example, the diagnostics and control module 15 may use the received data from the data module 14 to control a capacity of the compressor 10. The diagnostics and control module 15 may modulate the compressor capacity by selectively separating the orbiting scroll member 40 from the non-orbiting scroll member 48 via solenoid 66, by selectively toggling the compressor between an ON state and an OFF state, and/or through blocked-suction modulation.

In addition to simply transmitting the sensor data received from sensors 80, 82, 84, 86 and the non-measured parameters to the diagnostics and control module 15, the data module 14 may also use the sensor data received from sensors 80, 82, 84, 86 and/or the non-measured parameters to diagnose the compressor 10 and/or refrigeration system 11. Specifically, the processing circuitry 88 of the data module 14 may use the sensor data received from the sensors 80, 82, 84, 86 and the non-measured parameters to provide the diagnostics and control module 15 with a diagnosis of the compressor 10 and/or refrigeration system 11.

In addition to the foregoing, the data module 14 may alternatively provide a diagnosis of the compressor 10 and/or refrigeration system 11 directly to the processing circuitry 89 of the diagnostics and control module 15 for use in directly controlling operation of the compressor 10 and/or refrigeration system 11.

The diagnostics and control module 15 may use the diagnosis provided by the data module 14 for use in comparison to the diagnosis of the compressor 10 and/or refrigeration system 11 made by the processing circuitry 89 of the diagnostics and control module 15. In this manner, the diagnostics and control module 15 is able to verify the diagnostics made by the processing circuitry 89 by comparing the diagnostic made by the processing circuitry 89 with that of the processing circuitry 88.

In addition to transmitting the sensor data from sensors 80, 82, 84, 86, the non-measured operating parameters, and the diagnosis of the compressor 10 and/or refrigeration system 11 to the diagnostics and control module 15, the data module 14 may additionally or alternatively supply such sensor data, non-measured operating parameters, and/or diagnosis directly to an external system such as a computer or system controller 104 and/or hand-held device 106. The diagnostics and control module 15 may also supply the computer 104 and/or hand-held device 106 with the sensor data, non-measured operating parameters, and/or diagnosis received from the data module 14 as well as the diagnostics performed by the diagnostics and control module 15 for use by the computer 104 and/or hand-held device 106.

The computer 104 and/or hand-held device 106 may use the sensor data, non-measured operating parameters, and/or diagnosis to control, track and/or monitor operation of the compressor 10 and/or refrigeration system 11. For example, the computer 104 may be remotely located from the compressor 10 and/or refrigeration system 11 such that the compressor 10 and/or refrigeration system 11 may be diagnosed, controlled, and monitored from a remote location. Providing a hand-held device 106 with the sensor data, non-measured operating parameters, and/or diagnostics performed by the data module 14 and/or diagnostics and control module 15 provides a service technician with an operational history of a compressor 10 and/or refrigeration system 11 for use in servicing the compressor 10 and/or refrigeration system 11.

As shown in FIG. 8, the data module 14 and associated processing circuitry 88 may be separated from the diagnostics and control module 15 and associated processing circuitry 89. For example, the data module 14 and associated processing circuitry 88 may be positioned within the electrical enclosure 28 such that the data module 14 and associated processing circuitry 88 are mounted to the shell 17 of the compressor 10 while the diagnostics and control module 15 and associated processing circuitry 89 are remotely located from the compressor 10. Remotely locating the diagnostics and control module 15 from the data module 14 allows for remote control of the compressor 10 and/or refrigeration system 11.

While the diagnostics and control module 15 may be remotely located from the data module 14, the diagnostics and control module 15 may alternatively be received in the electrical enclosure 28 such that the diagnostics and control module 15 and associated processing circuitry 89 are mounted to the shell 17 of the compressor 10. FIG. 2 shows the data module 14 and associated processing circuitry 88 as well as the diagnostics and control module 15 and associated processing circuitry 88 being disposed generally within the electrical enclosure 28 and mounted to the shell 17 of the compressor 10. FIG. 10 schematically represents this relationship, whereby the data module 14 and diagnostics and control module 15 are integrated as a single unit. While the data module 14 and diagnostics and control module 15 are described as including separate processing circuitry 88, 89, respectively, when the data module 14 and diagnostics and control module 15 are incorporated into the electrical enclosure 28, the data module 14 and diagnostics and control module 15 may share processing circuitry.

While the data module 14 and diagnostics and control module 15 may both be received within the electrical enclosure 28 of the compressor 10, separating the diagnostics and control module 15 from the data module 14, such that the diagnostics and control module 15 is remotely located from the data module 14 and compressor 10, allows the data module 14 to be used with various diagnostic and control modules. Because the data module 14 essentially serves as a hub for receiving sensor data and for determining non-measured operating parameters of a compressor and/or refrigeration system, the data module 14 may be used with virtually any diagnostics and control module 15.

Original equipment manufacturers typically use different diagnostics and control modules and schemes. Therefore, a data module 14 that may be interchanged and used with any diagnostics and control module 15 allows a compressor 10 incorporating such a data module 14 to be used with virtually any diagnostics and control module 15.

Those skilled in the art may now appreciate from the foregoing that the broad teachings of the present disclosure may be implemented in a variety of forms. Therefore, while this disclosure has been described in connection with particular examples thereof, the true scope of the disclosure should no be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.

Claims

1. A compressor comprising a shell, a compression mechanism, a motor, a data module, and a compressor controller, said data module including a processor and a memory, said compressor controller including a processor and a memory, said data module receiving sensed data, storing sensed data in said memory, and communicating sensed data to said compressor controller, said compressor controller controlling a capacity of the compressor based on said sensed data and operable to communicate with a system controller of a refrigeration system.

2. The compressor of claim 1, wherein said data module processor determines non-measured operating parameters of at least one of the compressor and said refrigeration system based on said sensed data.

3. The compressor of claim 2, wherein said non-measured operating parameters include subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature.

4. The compressor of claim 2, wherein said data module communicates said non-measured operating parameters to at least one of said system controller and said compressor controller.

5. The compressor of claim 2, wherein said data module diagnoses at least one of the compressor and said refrigeration system based on at least one of said sensed data and said non-measured operating parameters.

6. The compressor of claim 5, wherein said data module communicates said diagnosis to at least one of said system controller and said compressor controller.

7. The compressor of claim 1, wherein said data module diagnoses at least one of the compressor and said refrigeration system based on said sensed data.

8. The compressor of claim 7, wherein said data module communicates said diagnosis to at least one of said system controller and said compressor controller.

9. The compressor of claim 1, wherein said compressor controller diagnoses at least one of the compressor and said refrigeration system based on said sensed data from said data module.

10. The compressor of claim 9, wherein said compressor controller communicates said diagnosis to said system controller.

11. The compressor of claim 1, wherein said data module and said compressor controller are attached to the compressor.

12. For a refrigeration system including a system controller in communication with a compressor controller associated with a compressor, a data module comprising a housing, a processor and a memory, said housing mountable on the compressor, said processor receiving sensed data, storing sensed data in said memory, and operable to communicate sensed data to the compressor controller.

13. The data module of claim 12, wherein said data module processor determines non-measured operating parameters of at least one of said compressor and said refrigeration system based on said sensed data.

14. The compressor of claim 14, wherein said non-measured operating parameters include subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature.

15. The data module of claim 13, wherein said data module processor communicates said non-measured operating parameters to at least one of said system controller and said compressor controller.

16. The data module of claim 13, wherein said data module processor diagnoses at least one of said compressor and said refrigeration system based on at least one of said sensed data and said non-measured operating parameters.

17. The data module of claim 13, wherein said data module processor communicates said diagnosis to at least one of said system controller and said compressor controller.

18. The data module of claim 12, wherein said data module processor diagnoses at least one of said compressor and said refrigeration system based on said sensed data.

19. The data module of claim 18, wherein said data module processor communicates said diagnosis to at least one of said system controller and said compressor controller.

20. The data module of claim 12, wherein said compressor controller diagnoses at least one of said compressor and said refrigeration system based on said sensed data from said data module processor.

21. The data module of claim 20, wherein said compressor controller communicates said diagnosis to said system controller.

22. A compressor control system comprising:

a compressor;

a compressor controller operable to diagnose and/or control said compressor; and

a data module associated with said compressor and in communication with said compressor controller, said data module receiving sensor data indicative of compressor performance, determining non-measured system operating parameters, and diagnosing said compressor based on at least one of said sensor data and said non-measured system operating parameters, said data module communicating said sensor data, said non-measured system operating parameters, and said diagnosis to said compressor controller.

23. The compressor of claim 22, wherein said compressor controller determines said non-measured system operating parameters based on said received sensor data and diagnoses said compressor based on at least one of said received sensor data and said determined non-measured system operating parameters, said compressor controller comparing said determined non-measured system operating parameters to said non-measured system operating parameters received from said data module and comparing said determined diagnosis to said diagnosis received from said data module.

24. A method comprising:

communicating sensor data to a data module;

processing said sensor data at said data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system;

processing at least one of said sensor data and said determined non-measured operating parameters at said data module to diagnose said at least one compressor and refrigeration system;

communicating said sensor data, said non-measured operating parameters, and said diagnosis to a system controller;

determining said non-measured operating parameters at said system controller based on said received sensor data;

determining said diagnosis at said system controller based on said received sensor data and said determined non-measured operating parameters;

comparing said received non-measured operating parameters to said determined non-measured operating parameters at said system controller; and

comparing said received diagnosis to said determined diagnosis at said system controller.

25. A method comprising:

communicating sensor data to a data module;

processing said sensor data at said data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system;

processing at least one of said sensor data and said non-measured operating parameters at said data module to diagnose said at least one compressor and refrigeration system;

storing at least one of said sensor data, said non-measured operating parameters, and said diagnosis in a memory of said data module;

communicating at least one of said sensor data, said non-measured operating parameters, and said diagnosis to a first system controller;

replacing said first system controller with a second system controller; and

communicating at least one of said stored sensor data, said stored non-measured operating parameters, and said stored diagnosis to said second controller.