REFRIGERANT UNIT SERVICE TOOL

Abstract

A method for tracking amount of refrigerant added or removed from an HVAC/refrigeration system includes fluidly coupling a service tool with an inner volume of the refrigeration system. The service tool includes a reservoir that stores and discharges a refrigerant into the refrigeration system or receives the refrigerant from the refrigeration system, and a sensing portion positioned along a fluid flow path between the reservoir and the inner volume of the refrigeration system. The method includes operating the service tool to transfer an amount of refrigerant between the inner volume of the refrigeration system and the reservoir of the service tool. The method includes obtaining a signal from a sensor of the sensing portion indicative of a flow rate of the amount of refrigerant over a time period that the refrigerant is transferred. The method includes determining the amount of refrigerant based on the signal obtained from the sensor.

Description

BACKGROUND

The present disclosure relates generally to an HVAC/refrigeration unit employing a refrigerant as a working fluid to provide either cooling or heating to a volume/space. More particularly, the present disclosure relates to a service tool for use with the HVAC/refrigeration unit and system, for adding and/or removing refrigerant from the system and processing information related to the refrigerant, the unit, and/or the system.

SUMMARY

One implementation of the present disclosure is a service tool for adding or removing refrigerant from a refrigeration system, according to some embodiments. In some embodiments, the service tool includes a reservoir, a tubular member, a sensing portion, and processing circuitry. The reservoir is configured to store and discharge a refrigerant into the refrigeration system or receive the refrigerant from the refrigeration system, according to some embodiments. In some embodiments, the tubular member is configured to removably fluidly couple with a service port of the refrigeration system. In some embodiments, the tubular member defines a fluid flow path between an inner volume of the refrigeration system and the reservoir of the service tool. In some embodiments, the sensing portion is positioned along the tubular member, and has a sensor configured to generate a signal indicative of a flow rate of the refrigerant through the sensing portion. In some embodiments, the processing circuitry is configured to obtain the signal from the sensor over a time period that refrigerant is added to or removed from the refrigeration system. In some embodiments, the processing circuitry is configured to determine at least one of an amount of refrigerant added to, removed from, or currently present in the refrigeration system based on the signal from the sensor. In some embodiments, the processing circuitry is configured to report at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system to a database or a cloud computing system.

In some embodiments, the service tool includes a rotor assembly positioned within the sensing portion, the rotor assembly configured to be driven by refrigerant as the refrigerant flows through the sensing portion in either direction. In some embodiments, the sensor is configured to measure an angular speed or a number of revolutions per unit of time of the rotor assembly.

In some embodiments, the processing circuitry is configured to obtain time-series data of the angular speed or the number of revolutions per unit of time of the rotor assembly over the time period that refrigerant is added to or removed from the refrigeration system. In some embodiments, the processing circuitry is configured to determine the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system based on the time-series data obtained from the sensor, a geometry of the sensing portion, and a density of the refrigerant.

In some embodiments, the service tool further includes a temperature sensor and a pressure sensor configured to measure a temperature and a pressure of the refrigerant as the refrigerant flows through the sensing portion. In some embodiments, the processing circuitry is configured to use the temperature and the pressure of the refrigerant to determine the density of the refrigerant.

In some embodiments, the processing circuitry is configured to report the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system to a smartphone. In some embodiments, the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system is determined based on the signal from the sensor are weight, mass, or volume values. In some embodiments, the refrigeration system is a refrigerated display case.

Another implementation of the present disclosure is a system for tracking an amount of refrigerant added to or removed from a refrigeration system, according to some embodiments. In some embodiments, the system includes a critically charged refrigeration system, a user device, and a service tool. In some embodiments, the critically charged refrigeration system is configured to circulate a refrigerant through a piping system to cool a space. In some embodiments, the user device is configured to communicate with a cloud computing system. In some embodiments, the service tool is configured to add or remove refrigerant from the critically charged refrigeration system. In some embodiments, the service tool includes a sensing portion positioned along the tubular member. In some embodiments, the sensing portion includes a sensor configured to generate a signal indicative of a flow rate of the refrigerant through the sensing portion. In some embodiments, the service tool includes processing circuitry configured to obtain the signal from the sensor over a time period that refrigerant is added to or removed from the critically charged refrigeration system. In some embodiments, the processing circuitry is configured to determine at least one of an amount of refrigerant added to, removed from, or currently present in the critically charged refrigeration system based on the signal from the sensor. In some embodiments, the processing circuitry is configured to report at least one of the amount of refrigerant added to, removed from, or currently present in the critically charged refrigeration system to a database or a cloud computing system.

In some embodiments, the service tool further comprises a reservoir configured to store and discharge the refrigerant into the critically charged refrigeration system or receive the refrigerant from the critically charged refrigeration system.

In some embodiments, the service tool further includes a tubular member configured to removably fluidly couple with a service port of the critically charged refrigeration system. In some embodiments, the tubular member defines a fluid flow path between an inner volume of the critically charged refrigeration system and the reservoir of the service tool.

In some embodiments, the service tool includes a rotor assembly positioned within the sensing portion. In some embodiments, the rotor assembly is configured to be driven by refrigerant as the refrigerant flows through the sensing portion in either direction. In some embodiments, the sensor is configured to measure an angular speed or a number of revolutions per unit of time of the rotor assembly.

In some embodiments, the processing circuitry is configured to obtain time-series data of the angular speed or the number of revolutions per unit of time of the rotor assembly over the time period that refrigerant is added to or removed from the critically charged refrigeration system. In some embodiments, the processing circuitry is configured to determine the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system based on the time-series data obtained from the sensor, a geometry of the sensing portion, and a density of the refrigerant.

In some embodiments, the service tool further includes a temperature sensor and a pressure sensor configured to measure a temperature and a pressure of the refrigerant as the refrigerant flows through the sensing portion. In some embodiments, the processing circuitry is configured to use the temperature and the pressure of the refrigerant to determine the density of the refrigerant.

In some embodiments, the processing circuitry is configured to report the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system to the user device. In some embodiments, the user device is a smartphone that operates as a bridge between the service tool and the database or cloud computing system.

In some embodiments, the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system determined based on the signal from the sensor are weight, mass, or volume values. In some embodiments, wherein the critically charged refrigeration system is a refrigerated display case.

Another implementation of the present disclosure is a method for tracking amount of refrigerant added or removed from a refrigeration system, according to some embodiments. In some embodiments, the method includes fluidly coupling a service tool with an inner volume of the refrigeration system. In some embodiments, the service tool includes a reservoir configured to store and discharge a refrigerant into the refrigeration system or receive the refrigerant from the refrigeration system, and a sensing portion positioned along a fluid flow path between the reservoir and the inner volume of the refrigeration system. In some embodiments, the method includes operating the service tool to transfer an amount of refrigerant between the inner volume of the refrigeration system and the reservoir of the service tool. In some embodiments, the method includes obtaining a signal from a sensor of the sensing portion indicative of a flow rate of the amount of refrigerant over a time period that the refrigerant is transferred between the inner volume of the refrigeration system and the reservoir of the service tool. In some embodiments, the method includes determining the amount of refrigerant based on the signal obtained from the sensor.

In some embodiments, fluidly coupling the service tool with the inner volume of the refrigeration system includes fluidly coupling a tubular member of the service tool with a service port of the refrigeration system.

In some embodiments, the service tool further includes a temperature sensor and a pressure sensor configured to measure a temperature and a pressure of the refrigerant as the refrigerant flows through the sensing portion. In some embodiments, the amount of refrigerant is determined using a density of the refrigerant and the signal obtained from the sensor. In some embodiments, the density of the refrigerant is determined based on the temperature and the pressure of the refrigerant as detected by the temperature sensor and the pressure sensor. In some embodiments, the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system that are determined based on the signal from the sensor are weight, mass, or volume values.

This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

FIG. 1 is a block diagram of a refrigerant tracking system including a service tool and a refrigeration system, according to some embodiments.

FIG. 2 is a diagram of the refrigeration system of the refrigerant tracking system of FIG. 1, according to some embodiments.

FIG. 3 is a diagram of the service tool of the refrigerant tracking system of FIG. 1 configured to measure an amount of refrigerant added to or removed from a refrigeration system, according to some embodiments.

FIG. 4 is a view of a portion of the service tool of FIG. 3 including a rotor assembly, according to some embodiments.

FIG. 5 is another view of the portion of the service tool of FIG. 3 including the rotor assembly and a sensor, according to some embodiments.

FIG. 6 is a diagram of a portion of the service tool of the refrigerant tracking system of FIG. 1 using a weight sensor, according to some embodiments.

FIG. 7 is a view of a portion of the service tool of the refrigerant tracking system of FIG. 1 using ultrasonic transducers, according to some embodiments.

FIG. 8 is a view of a portion of the service tool of the refrigerant tracking system of FIG. 1 including a temperature sensor and a pressure sensor, according to some embodiments.

FIG. 9 is a block diagram of the refrigerant tracking system of FIG. 1, according to some embodiments.

FIG. 10 is a flow diagram of a process for tracking an amount of refrigerant added to or removed from a refrigeration system or unit, according to some embodiments.

DETAILED DESCRIPTION

Before turning to the Figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Referring generally to the FIGURES, a service tool can measure an amount of refrigerant added or removed from the refrigeration system. The service tool may include processing circuitry and can communicate with a controller of the refrigeration system to obtain health data, performance data, etc. The service tool may also communicate with a smartphone that includes a mobile application. The smartphone may be usable by a technician to obtain image of a data plate of the refrigeration system for proper sorting of any data obtained that is associated with the refrigeration system. The systems and methods described herein advantageously facilitate tracking amounts of refrigerant that are added to or removed from refrigeration systems.

Refrigerant Tracking System

Overview

Referring to FIG. 1, a refrigerant tracking system 100 is configured to monitor, track, and report amounts of refrigerant consumed over a lifetime or a portion of lifetime of refrigeration equipment. The refrigerant tracking system 100 may work in combination with a service tool 124 to track amounts of refrigerant added or removed from the refrigeration system and to determine amounts of refrigerant consumed by the refrigeration equipment over its lifetime, amount of a certain type of refrigerant that has leaked from the refrigeration equipment (e.g., to the environment), etc.

Referring still to FIG. 1, the refrigerant tracking system 100 includes a cloud computing system 104, a refrigeration unit 108 (e.g., an HVAC/refrigeration system, a heat pump, refrigeration equipment, a refrigerator, a refrigerated display case, a critically charged refrigeration system, etc.), the service tool 124, and a user device 106. The refrigeration unit 108 includes a controller 102, one or more temperature sensors 114, one or more amperage sensors 116, one or more pressure sensors 118, one or more humidity sensors 120, and one or more leak detectors 112 (shown as leak detector 112a and leak detector 112b). The controller 102 is configured to obtain any temperature, pressure, amperage, humidity, etc., from the temperature sensors 114, the amperage sensors 116, the pressure sensors 118, or the humidity sensors 120. The controller 102 is also configured to obtain any leak detection from the leak detectors 112. In some embodiments, the temperature, pressure, or humidity sensor data provided to the controller 102 include temperature and humidity of a zone which the refrigeration unit 108 operates to cool. In some embodiments, the temperature or pressure is a temperature or pressure of a refrigerant of the refrigeration unit 108 at any position in a refrigeration loop. In some embodiments, the controller 102 is configured to obtain amperage of any compressor of the refrigeration unit 108.

It should be understood that the terms “refrigeration system” or “refrigeration unit” as used herein may refer to any system or equipment that leverages a refrigerant to cool or heat a space. In this way, the refrigeration unit 108 may be or include a heating, ventilation, or air-conditioning (HVAC) system or equipment, a heat pump, a refrigerated display case, a cooling system, a cooler, a refrigerator, a freezer, etc.

In some embodiments, the refrigeration unit 108 includes a charging port 122 and a plate 110. The plate 110 can include a code, a barcode, a quick response (QR) code, textual information, a serial number, a device identifier, etc., that is visible on the refrigeration unit 108 and can be scanned by the user device 106 (e.g., a smartphone, a tablet, etc.). In some embodiments, the charging port is configured to fluidly couple the service tool 124 with a refrigerant reservoir, with a conduit of the refrigeration loop, a tubular member of the refrigeration loop, etc. In some embodiments, the service tool 124 can be removably coupled with the refrigeration unit 108 via the charging port 122 so that the service tool 124 can charge (e.g., add refrigerant to the refrigeration unit 108) the refrigeration unit 108 or discharge the refrigeration unit 108 (e.g., remove refrigerant from the refrigeration unit 108).

In some embodiments, the service tool 124 includes a controller and/or a wireless transceiver configured to communicate with the controller 102. In some embodiments, the controller 102 is configured to communicate with the cloud computing system 104 and/or the user device 106. The cloud computing system 104 can represent multiple servers, processors, processing circuitry, a single server, a single processor, a single processing circuit, etc., configured to perform any of the operations and functions described herein.

When a technician arrives at the refrigeration unit 108, the technician may scan the plate 110 and establish communication with the controller 102 via a communications link (e.g., wireless communications) between the controller 102 and the user device 106. In some embodiments, the user device 106 communicates directly with the service tool 124. In some embodiments, the service tool 124 is configured to establish communication with the controller 102 through the user device 106. For example, the user device 106 may establish a local wireless local area network (WLAN), a hotspot, etc., and the service tool 124 and the controller 102 may join the network or the hotspot. In some embodiments, the service tool 124 is configured to report sensor data to the controller 102 indicating an amount of refrigerant that is added or removed from the refrigeration unit 108.

In some embodiments, the user device 106 is configured to determined, based on an image of the plate 110, a user input, a manually input serial number of the refrigeration unit 108, etc., an identifier (e.g., a serial number, an identification string, a specific identification (ID), etc.) for the refrigeration unit 108. In some embodiments, the user device 106 is configured to provide the identifier of the refrigeration equipment 108 to the cloud computing system 104. In some embodiments, the controller 102 is configured to provide the identifier of the refrigeration equipment 108 to the cloud computing system 104 with a corresponding amount of refrigerant that is added or removed from the refrigeration unit 108. The controller 102 may communicate with the service tool 124 directly or through the user device 106. In some embodiments, the controller 102 is configured to communicate with the cloud computing system 104 directly or through the user device 106. In some embodiments, the identifier of the refrigeration unit 108 is provided to the cloud computing system 104 along with a current date and the amount of refrigerant added or removed from the refrigeration unit 108.

Refrigeration System

Referring particularly to FIG. 2, a refrigeration system 200 is shown, according to some embodiments. The refrigeration system 200 may be included in the refrigeration unit 108, or the refrigeration unit 108 may be a component of the refrigeration system 200, all of which are fluidly coupled with each other in a loop via piping 210 (e.g., hoses, tubular members, conduits, etc.). The refrigeration system 200 is configured to cool a space (e.g., a volume, a refrigeration zone, etc.). The refrigeration system 200 includes a compressor 204, a condenser 206, an expansion valve 208, and an evaporator 202. The compressor 204 is configured to pressurize a refrigerant and drive the refrigerant through piping 210 to the condenser 206. The refrigerant passes through the condenser 206, cools and releases heat, and exits the condenser 206. The refrigerant is then driven through piping 210 to the expansion valve 208. The refrigerant passes through the expansion valve 208 and expands (to thereby cool) before entering the evaporator 202. The refrigerant is then provided to the evaporator 202 to absorb heat from the space to cool the space. After the refrigerant exits the evaporator 202, the refrigerant returns to the compressor 204.

The refrigeration system 200 also includes a pressure sensor 212 positioned on a suction side of the compressor 204. The pressure sensor 212 may be the pressure sensor 118 as shown in FIG. 1 and described in greater detail above. The pressure sensor 212 is configured to provide measurements of pressure of the refrigerant as the refrigerant enters the compressor 204. The refrigeration system 200 also includes a temperature sensor 214 that is positioned along the piping 210 before an inlet of the evaporator 202. The temperature sensor 214 can be the temperature sensor 114. In some embodiments, the temperature sensor 214 is configured to provide a temperature of the refrigerant prior to entry of the evaporator 202 to the controller 102. In some embodiments, the refrigeration system 200 includes a flow rate sensor 216 that is configured to measure a flow rate (e.g., volumetric flow rate, velocity, mass flow rate, etc.) (e.g., downstream of the expansion valve 208) and provide the flow rate (shown as Q) to the controller 102.

It should be understood that the refrigerant may be any type of refrigerant such as R32, 410A, R22, CO2, propane, etc., and the systems and methods described herein can apply to any refrigeration system or multiple refrigeration systems that use the same or different refrigerants.

The controller 102 can be configured to generate control signals for the compressor 204 and operate the compressor 204 based on any of the temperature, pressure, or flow rates obtained from the temperature sensor 214, the pressure sensor 212, or the flow rate sensor 216. In some embodiments, the controller 102 is configured to operate the compressor 204 using a closed loop control scheme (e.g., PID control, PI control, etc.). For example, the controller 102 can be configured to perform various control algorithms. In some embodiments, the charging port 122 is configured to allow the service tool 124 to fluidly couple with the charging port 122 so that the service tool 124 can remove refrigerant from the refrigeration system 200 and add new refrigerant from the refrigeration system 200, or add additional refrigerant to the refrigeration system 200.

Service Tool

Referring to FIGS. 3-5, the service tool 124 is shown in greater detail, according to some embodiments. In some embodiments, the service tool 124 is configured to fluidly couple with the piping 210 of the refrigeration system so that the service tool 124 can charge refrigerant into the piping 210 or discharge refrigerant from the piping 210.

The service tool 124 includes a canister 302 (e.g., a container, a tank, a reservoir, etc.) that is configured to store and discharge refrigerant into the piping 210 when the service tool 124 is fluidly coupled with the piping 210. In some embodiments, the canister 302 includes an inner volume 328 within which refrigerant is stored. In some embodiments, the canister 302 also stores a propellant gas that is compressed and configured to expand to drive refrigerant into the piping 210. In some embodiments, the canister 302 is removably coupled with a tubular member 304 (e.g., a pipe, a hose, etc.) through a neck 326. For example, an inner portion of the neck 326 can have seals and threads, interlocking portions, a quick disconnect interface, etc., configured to threadingly couple with the tubular member 304 or configured to interlock with the neck 326. The service tool 124 can also include a valve 330 that is transitionable between a closed position and an open position (e.g., by the technician). When the valve 330 is transitioned into the open position, a fluid flow path is defined between the inner volume 328 of the canister 302 and the piping 210 so that the refrigerant may discharge from the canister 302 into the piping 210 (e.g., when adding refrigerant to the refrigeration system 200), or may return from the piping 210 into the canister 302 (e.g., when removing refrigerant from the refrigeration system 200). When the valve 330 is transitioned into the closed position, a fluid flow path is limited between the inner volume 328 of the canister 302 and the piping 210.

The fluid flow path is defined between the inner volume 328 of the canister 302, through inner volume of the tubular member 304, through an inner volume of a sensing portion 306, through an inner volume of a pipe 324, and through an inner volume of a connector 308. The connector 308 may be the structural portion of the piping 210 that defines service port 122. The connector 308 can be a coupler (e.g., a quick-release coupler, a pressure fit coupler, an interlocking coupler, etc.) that is configured to receive the pipe 324 so that the pipe 324 fluidly couples with an inner volume of the piping 210. In some embodiments, the connector 308 and the pipe 324 are threadingly coupled with each other. In some embodiments, the connector 308 and the pipe 324 are removably coupled with each other. For example, when the technician arrives at the refrigeration system 200, the technician may couple the pipe 324 with the piping 210 by connecting the pipe 324 (e.g., a hose) with the connector 308.

The service tool 124 may include a pump 331 (e.g., an electric pump 331) that is configured to pump refrigerant out of the canister 302 and into the refrigeration system 200 (e.g., into the piping 210), or to pump refrigerant out of the refrigeration system 200 (e.g., out of the piping 210) and into the canister 302. In some embodiments, the pump 331 is configured to draw an electrical current (e.g., from a battery or power storage unit) and pump refrigerant (e.g., liquid refrigerant). The pump 331 can provide motor feedback (e.g., an amount of power drawn, a feedback speed of the motor, a voltage across the motor, etc.) which can be used (e.g., by the controller 102) to determine an amount of the refrigerant that is charged into the refrigeration system 200 or removed from the refrigeration system 200. In some embodiments, the pump 331 is optional or is usable in place of the sensing portion 306 and the functionality of the sensing portion 306 as described in greater detail below with reference to at least FIGS. 4-5.

In some embodiments, the sensing portion 306 is permanently coupled with the refrigeration system 200. The service tool 124 (e.g., the tubular member 304) may be removably coupleable with the sensing portion 306. In some embodiments, the connector 308 is formed at an end of the sensing portion 306 so that the service tool 124 can be removably coupled with the sensing portion 306. In some embodiments, newly installed refrigeration systems are equipped with the sensing portion 306 and a sensor for detecting an amount of refrigerant added or removed from the refrigeration system. The sensor of the sensing portion 306 may include a flywheel (e.g., as described in greater detail below with reference to FIGS. 4 and 5), a mass flow meter, a volume flow sensor, etc.

Referring particularly to FIGS. 4 and 5, the sensing portion 306 is shown in greater detail, according to some embodiments. The sensing portion 306 includes a rotor assembly 314 that is configured to be driven to rotate by a flow of refrigerant through the sensing portion 306. The rotor assembly 314 is a rotatable member that includes a plurality of blades 316 (e.g., fan blades, turbine blades, elongated members, etc.). The rotor assembly 314 also includes a central portion 318 with which the blades 316 are fixedly coupled or integrally formed. The central portion 318 is mounted on a shaft 320 that extends centrally through an inner volume of the sensing portion 306. The shaft 320 can be coupled on either end within a wall of the sensing portion 306 via bearings (e.g., ball bearings).

As refrigerant flows through the sensing portion 306 in either direction (e.g., into the piping system 210, or out of the piping system 210), the rotor assembly 314 is driven to rotate. A sensor 322 is configured to measure a number of rotations, when the shaft 320 has made a complete rotation, revolutions per minute (RPM) of the shaft 320, speed of the shaft 320, etc. In some embodiments, the sensor 322 is a tachometer, an RPM sensor, etc. In some embodiments, feedback from the sensor 322 (e.g., RPM of the shaft 320, speed of the shaft 320, number of revolutions of the shaft 320, etc.) is provided to the controller 102 (and/or the user device 106) for use in determining an amount of refrigerant added or removed from the refrigeration system 200.

Referring to FIG. 6, a diagram 600 shows an alternative embodiment for measuring an amount of refrigerant added to or removed from the refrigeration system 200. In some embodiments, the canister 302 is positioned within a housing 602 having walls and a floor 606. The canister 602 may rest upon the floor 606 which is movable relative to the housing 602. In some embodiments, a weight sensor 604 is positioned within or beneath the floor 606 and is configured to measure a weight of the canister 302. In other embodiments, the canister 302 is suspended from a ceiling of the housing 602, walls of the housing 602, etc., and the weight sensor 604 (e.g., a strain gauge) is positioned along an element used to suspend the canister 302. The weight sensor 604 can provide a weight of the canister 302 prior to and after adding or removing the refrigerant from the refrigeration system 200, and report weight measurements of the canister 302 to the controller 102 (and/or the user device 106) so that the controller 102 can determine an amount (e.g., a mass or weight) or quantity of refrigerant added to or removed from the refrigeration system 200.

Referring to FIG. 7, a diagram 700 shows an alternative embodiment for measuring speed of refrigerant added to or removed from the refrigeration system 200. In some embodiments, the sensing portion 306 includes a pair of ultrasonic transducers 702 that are configured to emit ultrasonic waves between each other. The ultrasonic transducers 702 are configured to emit ultrasonic waves in response to receiving electrical energy, and generate electrical energy (e.g., a signal) in response to receiving an ultrasonic wave. In some embodiments, the controller 102 is configured to measure an amount of time (e.g., a time of flight) it takes for the ultrasonic wave to travel from an upstream to a downstream one of the ultrasonic transducers 702, and also an amount of time it takes for the ultrasonic wave to travel from a downstream to an upstream one of the ultrasonic transducers 702. The controller 102 is configured to use a difference in the amounts of time to determine a speed of the refrigerant through the sensing portion 306.

Referring particularly to FIG. 8, a diagram 800 illustrates a temperature sensor 802 and a pressure sensor 804 positioned along the sensing portion 306 of the service tool 124. The temperature sensor 802 is configured to measure a temperature of the refrigerant flowing through the sensing portion 306 (e.g., flowing in either direction such as into the refrigeration system 200 or out of the refrigeration system 200). Similarly, the pressure sensor 804 is configured to measure a pressure of the refrigerant flowing through the sensing portion 306. The temperature sensor 802 and the pressure sensor 804 are configured to provide temperature and/or pressure readings to the controller 102. In some embodiments, the temperature sensor 802 and the pressure sensor 804 as shown in FIG. 8 are usable with any of the embodiments of the service tool 124 as shown in FIGS. 3-7. In some embodiments, the controller 102 is configured to use the temperature and the pressure obtained from the temperature sensor 802 and the pressure sensor 804 to determine the amount of refrigerant added or removed from the refrigeration system 200. In some embodiments, the controller 102 is configured to use temperature or pressure readings obtained from the refrigeration system 200 to determine the amount of refrigerant added or removed from the refrigeration system 200.

Wireless Communications and Implementation Architecture

Referring to FIGS. 1, 2, and 9, the service tool 124 may include a controller 910 which includes processing circuitry 912 including a processor 914 and memory 916. Processing circuitry 912 can be communicably connected to a communications interface such that processing circuitry 912 and the various components thereof can send and receive data via the communications interface. Processor 914 can be implemented as a general purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable electronic processing components.

Memory 916 (e.g., memory, memory unit, storage device, etc.) can include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present application. Memory 916 can be or include volatile memory or non-volatile memory. Memory 916 can include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present application. According to some embodiments, memory 916 is communicably connected to processor 914 via processing circuitry 912 and includes computer code for executing (e.g., by processing circuitry 912 and/or processor 914) one or more processes described herein.

The controller 102 is shown to include processing circuitry 602 including a processor 604 and memory 606. Processing circuitry 602 can be communicably connected to a communications interface such that processing circuitry 602 and the various components thereof can send and receive data via the communications interface. Processor 604 can be implemented as a general purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable electronic processing components.

Memory 606 (e.g., memory, memory unit, storage device, etc.) can include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present application. Memory 606 can be or include volatile memory or non-volatile memory. Memory 606 can include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present application. According to some embodiments, memory 606 is communicably connected to processor 604 via processing circuitry 602 and includes computer code for executing (e.g., by processing circuitry 602 and/or processor 604) one or more processes described herein.

In some embodiments, the controller 102 is implemented within a single computer (e.g., one server, one housing, etc.). In various other embodiments, controller 102 can be distributed across multiple servers or computers (e.g., that can exist in distributed locations).

The controller 102 (e.g., the processing circuitry 602) is shown receiving the sensor feedback from the service tool 124, and sensor data from any of the temperature sensor 214, the pressure sensor 212, and/or the flow rate sensor 216, or any other sensor of the refrigeration system 200. In some embodiments, the controller 102 is wirelessly communicably coupled with the service tool 124 (e.g., with the controller 910 of the service tool 124). In some embodiments, the controller 102 is configured to directly wirelessly communicate with any of the sensors of the service tool 124. In some embodiments, the service tool 124 (or sensors thereof) are configured to establish communication with the controller 102 through the user device 106, with the user device 106 acting as an intermediary or bridge device (e.g., to forward data between the service tool 124 and the controller 102).

The controller 102 is configured to obtain sensor feedback from the service tool 124 and sensor data from the system sensors 902. In some embodiments, the controller 102 is configured to determine an amount of refrigerant added or removed from the refrigeration system 200.

For example, if the service tool 124 includes sensors or detectors for measuring speed of the refrigerant through the sensing portion 306 (e.g., as shown in FIGS. 3-5, or as shown in FIG. 7), the controller 102 may use time-series data of a speed, v, volumetric flow rate {dot over (V)}, or RPM (e.g., angular speed) obtained from the sensor 322, or the ultrasonic transducers 702 to determine an amount of refrigerant added or removed from the refrigeration system 200. The controller 102 may also use the temperature and/or pressure of the refrigerant as obtained from the temperature sensor 802 and the pressure sensor 804 to determine a density of the refrigerant (e.g., based on a type of refrigerant that is added or removed, which may be obtained from the user device 106 based on scanned information of the plate 110 or input by a technician 908). The controller 102 can use the time-series data of the speed v, the volumetric flow rate or RPM obtained from the service tool 124 to determine a time-series of mass flow rate {dot over (m)} of the refrigerant into or out of the refrigeration system 200 or a time-series of weight flow rate {dot over (w)} across a time interval over which refrigerant is added or removed from the refrigeration system 200. In some embodiments, the controller 102 is configured to integrate the mass flow rate {dot over (m)} or the weight flow rate {dot over (w)} to determine a mass m or a weight w or refrigerant added or removed from the refrigeration system 200 (e.g., m_added and m_removed or w_added and w_removed). In some embodiments, the controller 102 is configured to integrate the volumetric flow rate {dot over (V)} to determine a volume V of refrigerant added or removed from the refrigeration system 200 (e.g., V_added or V_removed). The controller 102 can also use known geometry of the sensing portion 306 (e.g., a diameter 315) to determine amount of refrigerant added or removed (e.g., volume, weight, mass, etc.).

In some embodiments, the controller 102 is configured to count a number of revolutions of the rotor assembly 314 as refrigerant is added or removed from the refrigeration system 200. In some embodiments, the controller 102 is configured to use a predetermined relationship (e.g., an equation, a function, a curve fit equation, a regression of collected data, etc.) to determine a quantity (e.g., in terms of mass, weight, or volume) of refrigerant added or removed from the refrigeration system 200.

In some embodiments, the controller 102 is configured to receive the weight measurements from the weight sensor 604 before and after refrigerant is added or removed from the refrigeration system 200. In some embodiments, the controller 102 is configured to use a difference between the weight measurements before and after refrigerant is added or removed from the refrigeration system 200 to determine a weight, mass, quantity, or volume of refrigerant added or removed from the refrigeration system 200.

In some embodiments, any of the functionality of the controller 102 as described herein with reference to FIG. 3 is performed by the user device 106 or the cloud computing system 104. In some embodiments, any of the functionality of the controller 102 for determining an amount of refrigerant added or removed from the refrigeration system 200 is performed by the controller 910 (or processing circuitry 912 thereof) of the service tool 124, and the service tool provides determined quantities of refrigerant added or removed from the refrigeration system 200 to the controller 102. In some embodiments, the controller 910 of the service tool 124 is configured to use the sensor data obtained from any sensors of the service tool 124 to determine the amounts of refrigerant added and removed from the refrigeration system 200, and is configured to receive sensor data from the sensors (e.g., sensors 112, 114, 116, 118, 120, 212, 214, or 216) of the refrigeration system 200 via communications with the controller 102. In some embodiments, the service tool 124 (e.g., the controller 910 or the processing circuitry 912), the controller 102, and the user device 106 are configured to communicate with each other wirelessly via Wi-Fi, LoRa, Zigbee, Bluetooth, etc., or any other wireless communications protocol.

Process

Referring to FIG. 10, a process 1000 for determining an amount of refrigerant added to, removed from, or consumed by a refrigeration system, and for tracking refrigerant is shown, according to some embodiments. The process 1000 includes steps 1002-1016 and can be performed by the refrigerant tracking system 100.

Process 1000 includes providing a refrigeration system having a charging port for adding or removing refrigerant (step 1002), according to some embodiments. In some embodiments, the refrigeration system is the refrigeration system 200. In some embodiments, the charging port is the charging port 122, or a coupler that is configured to receive a tubular member to fluidly couple the tubular member with a refrigerant reservoir or one or more pipes of the refrigeration system 200.

Process 1000 includes coupling a charging device to the charging port (step 1004), according to some embodiments. In some embodiments, the charging device is the service tool 124. In some embodiments, the charging device is configured to add or remove refrigerant from the system. The charging device can include a tank or reservoir of refrigerant for adding refrigerant to the system. In some embodiments, the charging device includes an empty tank or reservoir for refrigerant that is removed from the refrigeration system (e.g., a refrigeration unit such as a refrigerated display case). In some embodiments, the tank is interchangeable so that a technician can fill an empty tank with refrigerant from the refrigeration system, then replace the tank with a tank that is full of new refrigerant, and add the new refrigerant to the refrigeration system. In some embodiments, the technician does not remove the refrigerant from the system but only adds new or additional refrigerant to charge the refrigeration system to full. Coupling the charging device with the charging port can define a fluid flow path between a tank or reservoir of the charging device and an inner volume or refrigerant reservoir of the refrigeration system. Step 1004 can be performed by a technician when the technician arrives at the refrigeration system to perform servicing.

Process 1000 includes operating the charging device to add an amount of refrigerant to the refrigeration system and/or to remove an amount of refrigerant from the refrigeration system (step 1006), according to some embodiments. In some embodiments, the charging device includes a pump or compressor that is configured to drive refrigerant into or out of the refrigeration system. Refrigerant removed from the refrigeration system can be stored in the reservoir or tank of the charging device. Refrigerant added to the refrigeration system can be driven from the reservoir or tank of the charging device into the refrigeration system. Step 1006 can be performed by the technician and the pump or compressor. In some embodiments, the reservoir or the tank includes a propellant gas to discharge the refrigerant into the refrigeration system.

Process 1000 includes obtaining a sensor signal from a sensor of the charging device (step 1008), according to some embodiments. In some embodiments, the sensor signal is obtained from any of the sensor 322, the weight sensor 604, the ultrasonic transducer 702, the temperature sensor 802, the pressure sensor 804, etc. In some embodiments, the sensor signal is a number of revolutions of the rotor assembly 314, a number of revolutions per minute of the rotor assembly 314, a weight of the canister 302 (e.g., before or after adding or removing refrigerant), time of flight of ultrasonic signals as provided by the ultrasonic transducers 702, etc. In some embodiments, the sensor signal is obtained by a controller (e.g., controller 910, or controller 102).

Process 1000 includes determining, based on the sensor signal, the amount of refrigerant added to the refrigeration system or the amount of refrigerant removed from the refrigeration system (step 1010), according to some embodiments. In some embodiments, step 1010 is performed by the controller 910, the controller 102, the user device 106, or the cloud computing system 104. In some embodiments, step 1010 include determining a mass, volume, or weight of refrigerant that is added or removed from the refrigeration system. In some embodiments, step 1010 includes using one or more relationships, functions, equations, etc., to determine a speed or flow rate of refrigerant that is added or removed from the refrigeration system (e.g., flowing through the sensing portion 306), and integrating the speed or flow rate of refrigerant to determine a quantity of refrigerant provided into or removed from the refrigeration system.

Process 1000 includes determining, based on the amount of refrigerant added or removed from the refrigeration system, and a type of the refrigerant, a corresponding carbon emission or environmental impact (step 1012), according to some embodiments. In some embodiments, step 1012 is performed by the controller 102, the controller 910, the user device 106, or the cloud computing system 104. In some embodiments, determining the corresponding carbon emission includes determining a carbon dioxide (CO2) emission or environmental impact of the amount of refrigerant that is put into service in the refrigeration system (e.g., the amount of refrigerant added to the refrigeration system). In some embodiments, the corresponding CO2 emissions or environmental impact is determined based on a value of global-warming potential (GWP) for the type of the refrigerant, and the amount of refrigerant added to the refrigeration system.

Process 1000 includes obtaining a serial number of the refrigeration system or a device ID of the refrigeration system by scanning a data plate or by receiving a manual input (step 1014), according to some embodiments. In some embodiments, step 1014 is performed by capturing an image of the data plate (e.g., an image of a QR code, an image of a barcode, an image of textual information, etc.) with a smartphone or user device, and performing an image analysis based on the image to determine the serial number of the refrigeration system or to determine the device ID of the refrigeration system. In some embodiments, the technician may manually input the serial number or the device ID (e.g., via the user device or the smartphone). In some embodiments, the device ID is a unique identifier of the refrigeration system.

Process 1000 includes reporting the amount of refrigerant added or removed from the refrigeration system to a tracking system (step 1016), according to some embodiments. In some embodiments, the amount of refrigerant added or removed from the refrigeration system is tied with or associated with the device ID or serial number of the refrigeration system. In some embodiments, any data obtained from the refrigeration system (including operational data, efficiency data, COP, amount of refrigerant added, amount of refrigerant removed, amount of refrigerant that the refrigeration system has leaked, etc.) is stored in a database of the tracking system. In some embodiments, step 1016 includes transmitting, via the controller 910, or the user device 106, the amount of refrigerant added or removed from the refrigeration system to the cloud computing system 104 with the device ID or serial number of the refrigeration system for which the amount of refrigerant is added or removed.

Configuration of Exemplary Embodiments

As utilized herein, the terms “approximately”, “about”, “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claim.

It should be noted that the terms “exemplary” and “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like, as used herein, mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent, etc.) or moveable (e.g., removable, releasable, etc.). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” “between,” etc.) are merely used to describe the orientation of various elements in the figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.

It is important to note that the construction and arrangement of the systems as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. It should be noted that the elements and/or assemblies of the components described herein may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from scope of the present disclosure or from the spirit of the appended claim.

Claims

1. A service tool for adding or removing refrigerant from a refrigeration system, the service tool comprising:

a reservoir configured to store and discharge a refrigerant into the refrigeration system or receive the refrigerant from the refrigeration system;

a tubular member configured to removably fluidly couple with a service port of the refrigeration system, the tubular member defining a fluid flow path between an inner volume of the refrigeration system and the reservoir of the service tool;

a sensing portion positioned along the tubular member, the sensing portion comprising a sensor configured to generate a signal indicative of a flow rate of the refrigerant through the sensing portion; and

processing circuitry configured to: obtain the signal from the sensor over a time period that refrigerant is added to or removed from the refrigeration system; and determine at least one of an amount of refrigerant added to, removed from, or currently present in the refrigeration system based on the signal from the sensor; and report at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system to a database or a cloud computing system.

2. The service tool of claim 1, wherein the service tool comprises a rotor assembly positioned within the sensing portion, the rotor assembly configured to be driven by refrigerant as the refrigerant flows through the sensing portion in either direction, wherein the sensor is configured to measure an angular speed or a number of revolutions per unit of time of the rotor assembly.

3. The service tool of claim 2, wherein the processing circuitry is configured to:

obtain time-series data of the angular speed or the number of revolutions per unit of time of the rotor assembly over the time period that refrigerant is added to or removed from the refrigeration system;

determine the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system based on the time-series data obtained from the sensor, a geometry of the sensing portion, and a density of the refrigerant.

4. The service tool of claim 3, wherein the service tool further comprises a temperature sensor and a pressure sensor configured to measure a temperature and a pressure of the refrigerant as the refrigerant flows through the sensing portion, wherein the processing circuitry is configured to use the temperature and the pressure of the refrigerant to determine the density of the refrigerant.

5. The service tool of claim 1, wherein the processing circuitry is configured to report the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system to a smartphone.

6. The service tool of claim 1, wherein the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system determined based on the signal from the sensor are weight, mass, or volume values.

7. The service tool of claim 1, wherein the refrigeration system is a refrigerated display case.

8. A system for tracking an amount of refrigerant added to or removed from an heating, ventilation, and air-conditioning (HVAC) or refrigeration system, the system comprising:

a critically charged refrigeration system configured to circulate a refrigerant through a piping system to cool a space;

a user device configured to communicate with a remote system; and

a service tool for adding or removing refrigerant from the critically charged refrigeration system, the service tool comprising: a sensing portion positioned along the tubular member, the sensing portion comprising a sensor configured to generate a signal indicative of a flow rate of the refrigerant through the sensing portion; and processing circuitry configured to: obtain the signal from the sensor over a time period that refrigerant is added to or removed from the critically charged refrigeration system; and determine at least one of an amount of refrigerant added to, removed from, or currently present in the critically charged refrigeration system based on the signal from the sensor; and report at least one of the amount of refrigerant added to, removed from, or currently present in the critically charged refrigeration system to the cloud computing system.

9. The system of claim 8, wherein the service tool further comprises a reservoir configured to store and discharge the refrigerant into the critically charged refrigeration system or receive the refrigerant from the critically charged refrigeration system.

10. The system of claim 8, wherein the service tool further comprises a tubular member configured to removably fluidly couple with a service port of the critically charged refrigeration system, the tubular member defining a fluid flow path between an inner volume of the critically charged refrigeration system and the reservoir of the service tool.

11. The system of claim 8, wherein the service tool comprises a rotor assembly positioned within the sensing portion, the rotor assembly configured to be driven by refrigerant as the refrigerant flows through the sensing portion in either direction, wherein the sensor is configured to measure an angular speed or a number of revolutions per unit of time of the rotor assembly.

12. The system of claim 11, wherein the processing circuitry is configured to:

obtain time-series data of the angular speed or the number of revolutions per unit of time of the rotor assembly over the time period that refrigerant is added to or removed from the critically charged refrigeration system;

determine the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system based on the time-series data obtained from the sensor, a geometry of the sensing portion, and a density of the refrigerant.

13. The system of claim 12, wherein the service tool further comprises a temperature sensor and a pressure sensor configured to measure a temperature and a pressure of the refrigerant as the refrigerant flows through the sensing portion, wherein the processing circuitry is configured to use the temperature and the pressure of the refrigerant to determine the density of the refrigerant.

14. The system of claim 8, wherein the processing circuitry is configured to report the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system to the user device, wherein the user device is a smartphone that operates as a bridge between the service tool and the cloud computing system.

15. The system of claim 8, wherein the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system determined based on the signal from the sensor are weight, mass, or volume values.

16. The service tool of claim 8, wherein the critically charged refrigeration system is a refrigerated display case.

17. A method for tracking amount of refrigerant added or removed from a refrigeration system, the method comprising:

fluidly coupling a service tool with an inner volume of the refrigeration system, the service tool comprising a reservoir configured to store and discharge a refrigerant into the refrigeration system or receive the refrigerant from the refrigeration system, and a sensing portion positioned along a fluid flow path between the reservoir and the inner volume of the refrigeration system;

operating the service tool to transfer an amount of refrigerant between the inner volume of the refrigeration system and the reservoir of the service tool;

obtaining a signal from a sensor of the sensing portion indicative of a flow rate of the amount of refrigerant over a time period that the refrigerant is transferred between the inner volume of the refrigeration system and the reservoir of the service tool; and

determining the amount of refrigerant based on the signal obtained from the sensor.

18. The method of claim 17, wherein fluidly coupling the service tool with the inner volume of the refrigeration system comprises fluidly coupling a tubular member of the service tool with a service port of the refrigeration system.

19. The method of claim 17, wherein the service tool further comprises a temperature sensor and a pressure sensor configured to measure a temperature and a pressure of the refrigerant as the refrigerant flows through the sensing portion, wherein the amount of refrigerant is determined using a density of the refrigerant and the signal obtained from the sensor, the density of the refrigerant determined based on the temperature and the pressure of the refrigerant as detected by the temperature sensor and the pressure sensor.

20. The method of claim 17, wherein the at least one of the amount of refrigerant added to, removed from, or currently present in the refrigeration system determined based on the signal from the sensor are weight, mass, or volume values.