Patent Application
20170010031
The present invention relates to an air conditioner and particularly, to an air conditioner that measures changes in electric current and electric power supplied to an outdoor fan motor to infer frost formation on a heat exchanger.
Heretofore, as a method of inferring frost formation on a heat exchanger, there has been known detecting an increase in electric current flowing through an outdoor fan motor to perform a defrosting operation.
Japanese Patent Application Laid-Open No. 60-144546
Where the rotational speed of an outdoor fan (hereafter referred to as fan rotational speed) is fixed in a heating operation condition, an electric current flowing through an outdoor fan motor (hereinafter referred to as fan electric current) also increases together with an increase in the amount of frost formation on an outdoor heat exchanger, and thus, it becomes possible to detect the frost formation and to make a defrosting judgment. However, in recent years, with energy-saving capabilities of equipments taken into consideration, it has been requested to control the fan rotational speed properly to meet a load and thereby to decrease the electric power consumption by the outdoor fan motor (hereafter referred to as fan electric power). Since a decrease in the fan rotational speed causes the fan electric current to decrease as well, it becomes unable to detect an increase of electric current caused by frost formation.
Further, in a control wherein the fan rotational speed is regulated by the voltage applied to the outdoor fan motor (hereafter referred to as fan voltage), the fan voltage is lowered to decrease the fan rotational speed. When a constant torque control is performed in this case, the decrease in the fan rotational speed hardly results in the decrease in the fan electric current.
For this reason, an object of the present invention is to be capable of coping with the situation of changes in fan rotational speed in inferring frost formation during a heating operation, wherein the state of frost formation on a heat exchanger can properly be inferred to make a defrosting judgment even under the characteristic that as is the case of a torque constant control of the fan motor, the current value does not correspond to the fan rotational speed.
In order to accomplish the foregoing object, the present invention resides in an air conditioner comprising:
an outdoor heat exchanger that performs a heat exchange between refrigerant flowing through an interior thereof and air;
an outdoor fan that sends air to the outdoor heat exchanger;
an outdoor fan motor that drivingly rotates the outdoor fan;
an outdoor fan inverter that makes a desired electric current flow through the outdoor fan motor;
a current detector that detects electric current flowing through the outdoor fan motor; and
a control section that controls the outdoor fan inverter so that the rotational speed of the outdoor fan motor becomes a target rotational speed;
wherein the control section starts a defrosting operation of the outdoor heat exchanger based on a detection value of the current detector in a heating operation.
According to the present invention, it becomes possible to make a defrosting judgment properly even when the fan rotational speed changes. Furthermore, even under the characteristic that as is the case of a torque constant control of the fan motor, the electric current value does not correspond to the fan rotational speed, it becomes possible to infer the state of frost formation on the heat exchanger properly and to make a judgment for defrosting.
Other technical problems, configurations and advantageous effects than those aforementioned will be further clarified in the following description of embodiments.
Hereinafter, embodiments of an air conditioner in the present invention will be described with reference to the drawings.
Hereinafter, a first embodiment of the air conditioner in the present invention will be described with reference to the drawings.
Here, in the outdoor heat exchanger 14, it may occur that when subjected to latent heat exchange in the heat exchange with the outdoor air, water vapor in the atmosphere is solidified on the exchanger's fin surface to turn to droplets. Further, where the evaporating temperature is lower than 0° C., the droplets are subjected to heat exchange on the fins and are solidified to become frost. The frost adhered grows up together with the continuous operation of the air conditioner to make the fins clogged. This causes a drop in the fan air flow rate, a deterioration of a heat transfer coefficient and the like thereby to obstruct the heat exchanger from transferring heat, and hence, it is necessary to perform defrosting.
Next, description will be made regarding the flow of refrigerant and a defrosting phenomenon in a defrosting operation. The defrosting operation in the present embodiment is implemented by changing the four-way valve 13 to the broken-line position contrary to the heating operation, wherein the flow of the refrigerant is in the same direction as that in a cooling operation. The defrosting operation is an operation that is carried out by a so-called reverse cycle. The high-pressure gas refrigerant compressed by the compressor 11 enters the four-way valve 13 to be send to the outdoor heat exchanger 14, and the high-pressure gas refrigerant is subjected to heat exchange with the frost adhered and is condensed to turn to high-pressure liquid refrigerant. Incidentally, during the defrosting, an outdoor fan 19 is stopped for restraining the loss of heat radiation to the outside air. Here, in the outdoor heat exchanger 14, the frost adhered melts into water and drops by the gravity. Thus, the clogging of the fins is removed, whereby the heat transfer performance of the heat exchanger can be revived. The condensed high-pressure liquid refrigerant passes through the outdoor expansion valve 15 to be sent to the indoor unit 40. Then, after being throttled by the indoor expansion valve 42, the liquid refrigerant passes through the indoor heat exchanger 41, the outdoor unit 10 and the four-way valve 13 to be sent to the compressor, so that the liquid refrigerant is again circulated in the refrigerating cycle. Incidentally, during the defrosting, the indoor fan is also controlled to be held in a fan stop state for the purpose of not generating cold air, and thus, it is designed that active heat exchange is not to be done. Therefore, all of the liquid refrigerant throttled by the indoor expansion valve 42 is not gasified in dependence on the duration of the defrosting operation, and thus, it may occur that the refrigerant is returned to the outdoor unit in the form of two phases including gas and liquid.
Further, the outdoor fan 19 will be described.
A rotational speed command is sent from the controller 61 to an outdoor fan inverter 21, and a desired electric current or voltage is sent from the outdoor fan inverter 21 to the outdoor fan motor 20, so that the outdoor fan motor 20 drivingly rotates the outdoor fan 19. Thus, the outdoor fan 19 is rotated to generate air of a proper quantity. It is to be noted that the electric current or voltage sent to the fan motor 20 is detected by a current detector or a voltage detector for the outdoor fan inverter 21 and that the controller 61 (control section) controls the outdoor fan inverter 21 to make the rotational speed of the outdoor fan motor 20 become a target rotational speed.
The air passing through the outdoor heat exchanger 14 flows in a direction toward the outdoor fan 19 and finally flows out toward the downstream side (in the upper direction in
Judgments for frost formation and defrosting will be described specifically. In the present embodiment, the control section (controller 61) controls the air conditioner to start a defrosting operation of the outdoor heat exchanger 14 based on a detection value of the current detector in the heating operation. When the fan rotational speed is f1, frost formation is absent at the early stage of the heating operation, and thus, the detection value A1 of the current detector becomes equivalent to the base value of the fan electric current (A1≈A1base). As the frost formation proceeds, the fan electric current (the detection value of the current detector) increases, and when the fan electric current (the detection value of the current detector) goes beyond the defrosting judgment value (A1≧A1def), the control section (controller 61) judges that the amount of the frost formation has increased, and starts a defrosting operation of the outdoor heat exchanger 14.
After the defrosting operation, the heating operation is started again, and then, the fan electric current (the detection value of the current detector) becomes equivalent to the base value of the fan electric current (A1≈A1base). Incidentally, the base value of the fan electric current may be stored in a storage unit of the control section (controller 61) in advance or the fan electric current upon completion of the defrosting may be replaced as the base value of the fan electric current. Furthermore, the defrosting judgment value of the fan electric current may be stored in the storage unit of the control section (controller 61) in advance or may be calculated as an increase rate relative to the base value as expressed in Expression (1).
A1def=K1×A1base (1)
Here, if the fan rotational speed were reduced from f1 to f2 with the base value and the defrosting judgment value held as they are, the fan electric current at the early stage would become smaller than the base value of the fan electric current (A2<A1base). Even if the fan electric current increased as the frost formation further proceeds, the fan electric current would be a current equivalent to the base value (A2≈A1base) and would not reach the defrosting judgment value (A2<A1def), and thus, the defrosting operation would not begin.
For the purpose of preventing the occurrence of such a situation, there are given a base value (A2base) and a defrosting judgment value (A2def) which correspond to the rotational speed when the same changes. That is, in the present embodiment, the defrosting judgment value of the fan current (the detection value of the current detector) is set to become larger as the rotational speed of the outdoor fan 19 increases.
In further detailed description, as shown in
Then, in the heating operation, the control section (controller 61) starts a defrosting operation of the outdoor heat exchanger 14 when the rotational speed of the outdoor fan motor 20 is the first rotational speed (f1) and when the detection value of the current detector becomes equal to or higher than the first defrosting judgment value (A1def), and also starts the defrosting operation of the outdoor heat exchanger 14 when the rotational speed of the outdoor fan motor 20 is the second rotational speed (f2) and when the detection value of the current detector becomes equal to or higher than the second defrosting judgment value (A2def).
Where the outdoor fan 19 is placed under a step control, base values and defrosting judgment values of the fan electric current (detection value of the current detector) that correspond to respective steps may beforehand be stored in the storage unit of the control section (controller 61). Further, since the rotational speed is continuously changed under the inverter control, the base values and the defrosting judgment values, if stored in the storage unit of the control section (controller 61) for respective rotational speeds, would cause a problem in storage capacity and therefore, may be calculated by using Expressions (2) and (3) shown below.
A2base=A1base×(f2/f1)n (2)
A2def=K2×A2base (3)
The base value may be obtained through conversion under the idea that it is proportional to the exponential multiplier of the rotational speed change rate like Expression (2). Further, the defrosting judgment value may be obtained by effecting a conversion to multiply the base vale with the current increase rate like Expression (3). That is, in the present embodiment, a storage unit is provided that stores the first base value (A1base), another value, that is, the second base value (A2base), the first defrosting judgment value (A1def) or the second defrosting judgment value (A2def) can be calculated based on the base value (e.g., A1base) stored in the storage unit and the rotational speeds (f1, f2) of the outdoor fan motor 20, as expressed in Expression (2) and Expression (3). Regarding the current increase rate K2, in the case of the step control of the outdoor fan, those values corresponding to respective steps may beforehand be stored in the storage unit of the control section (controller 61).
Here, since the rotational speed is continuously changed under the inverter control, a problem would arise in storage capacity if the current increase rates K2 for respective rotational speeds were stored in the storage unit of the control section (controller 61). Therefore, by considering the current increase rate K2 of Expression (3) as being almost equal to the current increase rate K1 of Expression (1) (K2≈K1), the same current increase rate K1 may be used. By so doing, the storage capacity of the controller can be relieved from being burdened.
Incidentally, in Expression (2) of Embodiment 1, the second base value (A2base) and the second defrosting judgment value (A2def) are calculated by compensating the first base value (A1base) for the rotational speed, and the detection for the frost formation is made by the comparison of the current value A2 during the heating operation with the second defrosting judgment value (A2def). Alternatively, without compensating the first base value (A1base) for the rotational speed, the detection for the frost formation may be made by the comparison between the first base value (A1base) and a compensated A2 into which the value A2 during the heating operation is compensated by being compensated for the rotational speed as expressed in Expression (4).
Compensated A2=A2×(f1/f2)n (4)
Hereafter, a second embodiment of the air conditioner according to the present invention will be described with reference to the drawings. Description will be omitted of the same configuration as the embodiment.
The left graph in
On the other hand, when frost formation takes place, the fan electric current becomes large at a high rotational speed, and the defrosting judgment value also becomes large at the high rotational speed (A1def>A2def). Thus, the current increase rate K2 of Expression (3) and the current increase rate K1 of Expression (1) described in Embodiment 1 do not become equal, wherein one at the high rotational speed becomes large (K2<K1). Although in this situation, it is required to have values for respective fan rotational speeds and to have the values stored in the storage unit of the control section (controller 61) in advance, there is a limit to the storage capacity. Further, since a characteristic like that in Embodiment 1 aforementioned is shown in a range higher than the fan rotational speed f1, one whose characteristic changes in a mid course is hard to be used in defrosting judgment.
The solid line shows the fan electric power in the absence of frost formation and has a characteristic that the fan electric power also increases as the fan rotational speed increases. Further, the broken line shows the fan electric power in the case where the amount of the frost formation is very large. In comparison with the fan electric power in the absence of frost formation, it can be grasped that the value of the electric power increases. When the fan electric power increases beyond the value specified by the broken line, the performance of the heat exchanger goes down remarkably due to excessive frost formation, and thus, the implementation of the defrosting becomes necessary. In the present embodiment, the fan electric power indicated by the broken line at the time of excessive frost formation is defined as a defrosting judgment value at which a start of defrosting is necessary, while the fan electric power indicated by the solid line in the absence of frost formation is defined as a base value that makes the defrosting unnecessary.
Frost formation and defrosting judgments will be described specifically. In the present embodiment, the control section (controller 61) controls the air conditioner to start the defrosting operation of the outdoor heat exchanger 14 when the electric power (fan electric power) calculated based on the detection values of the current detector and the voltage detector during the heating operation becomes equal to or higher than the defrosting judgment value. Here, when the fan rotational speed is f1, the frost formation is absent at the early stage of the heating operation, and thus, the electric power value (fan electric power) calculated based on the detection values of the current detector and the voltage detector becomes equivalent to the base value of the fan electric power (W1≈W1base).
The fan electric power increases as the frost formation proceeds, and when the electric power value (fan electric power) calculated based on the detection values of the current detector and the voltage detector becomes equal to or higher than the defrosting judgment value (W1≧W1def), the control section (controller 61) judges that the frost formation amount has increased, and starts the defrosting operation of the outdoor heat exchanger 14.
After this defrosting operation, the heating operation is started again, and thus, the electric power value (fan electric power) calculated based on the detection values of the current detector and the voltage detector becomes equivalent to the base value of the fan electric power (W1≈W1base). Incidentally, the base value of the fan electric power may beforehand be stored in the storage unit of the control section (controller 61). Alternatively, the fan electric power upon completion of the defrosting may be replaced as the base value of the fan electric power. Furthermore, the defrosting judgment value of the fan electric power may beforehand be stored in the storage unit of the control section (controller 61) or may be calculated in terms of an increase rate relative to the base value as expressed by Expression (5).
W1def=L1×W1base (5)
If the fan rotational speed were decreased from f1 to f2 with the base value and the defrosting judgment value held as they are, the base value of the fan electric power at the early stage of the heating operation would become smaller (W2<W1base). Even if the fan electric power increased as the frost formation further proceeds, the fan electric power would be the power that is equivalent to the base value (W2≈W1base) and lower than the defrosting judgment value (W2<W1def), whereby the defrosting could not be performed.
In order to prevent such a situation from arising, it is designed that where the rotational speed is changed, a base value (W2base) and a defrosting judgment value (W2def) are given in correspondence with the changed rotational speed. Here, in the present embodiment, a set value of the fan electric power for the defrosting judgment (electric power value calculated based on the detection values of the current detector and the voltage detector) is set to become larger as the rotational speed of the outdoor fan 19 increases.
Where the outdoor fan 19 is placed under the step control, values corresponding to respective steps may beforehand be stored in the storage unit of the control section (controller 61). Further, since the rotational speed is continuously changed under the inverter control, a problem would arise in storage capacity if the values for respective rotational speeds were stored in the storage unit of the control section (controller 61). Therefore, the values may be calculated by using Expressions (6) and (7) shown below.
W2base=W1base×(f2/f1)n (6)
W2def=L2×W2base (7)
The base value may be obtained through conversion under the idea that it is proportional to the exponential multiplier of the rotational speed change rate as expressed in Expression (6). Further, the defrosting judgment value may be obtained by effecting a conversion to multiply the base vale with the electric power increase rate like Expression (7). Regarding the electric power increase rate L2, where the outdoor fan is placed under the step control, values corresponding to respective steps may beforehand be stored in the storage unit of the control section (controller 61). Since the rotational speed is continuously changed under the inverter control, a problem would arise in storage capacity if the values for respective rotational speeds were stored in the storage unit of the control section (controller 61). Therefore, by considering the electric power increase rate L2 of Expression (7) and the electric power increase rate L1 of Expression (5) as being almost equal (L2≈L1), the same rate L1 may be used. By so doing, the storage capacity of the controller can be relieved from being burdened. The control that starts the defrosting operation of the control section (controller 61) based on these values are the same as that in Embodiment 1 and hence, is omitted from being described in detail.
Incidentally, in Embodiment 2, although the base value and the defrosting judgment value are compensated for the rotational speed, there may be taken a method in which the detected current value is compensated for the rotational speed without compensation on the base value and the defrosting judgment value.
10 Outdoor unit
11 Compressor
13 Four-way valve
14 Outdoor heat exchanger
15 Outdoor expansion value
19 Outdoor fan
20 Outdoor fan motor
21 Outdoor fan inverter
40 Indoor unit
41 Indoor heat exchanger
42 Indoor expansion value
61 Controller (control section)
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2014/059074 | 3/28/2014 | WO | 00 |
