Patent Grant
10539358
This application is a U.S. national stage application of International Application No. PCT/JP2014/069972 filed on Jul. 29, 2014, which claims priority to Japanese Patent Application No. 2013-174790 filed on Aug. 26, 2013, the disclosures of which are incorporated herein by reference.
The present invention relates to an air-conditioning apparatus and a refrigerant leakage detection method. The present invention particularly relates to an air-conditioning apparatus that performs a refrigeration cycle using a refrigerant with a low global warming potential, and a refrigerant leakage detection method for use in the air-conditioning apparatus.
Conventionally, “HFC refrigerants” such as non-flammable R410A have been used as a refrigerant for a refrigeration cycle performed by an air-conditioning apparatus. Unlike conventional “HCFC refrigerants” such as R22, R410A has an ozone depletion potential (hereinafter referred to as “ODP”) of zero and does not damage the ozone layer. However, R410A has the property of a high global warming potential (hereinafter referred to as “GWP”).
Therefore, as part of prevention of global warming, studies are underway to shift from HFC refrigerants with a high GWP such as R410A to refrigerants with a low GWP.
Candidates for such a low-GWP refrigerant include HC refrigerants such as natural refrigerants R290 (C3H8; propane) and R1270 (C3H6; propylene). However, unlike non-flammable R410A, these refrigerants are highly flammable, and therefore attention needs to be paid to refrigerant leakage.
Candidates for such a low-GWP refrigerant also include HFC refrigerants that do not have a carbon double bond in their composition, such as R32 (CH2F2; difluoromethane) with a lower GWP than R410A, for example.
Candidates for such a refrigerant also include halogenated hydrocarbons that are a type of HFC refrigerant, similar to R32, and that have a carbon double bond in their composition. Examples of such halogenated hydrocarbons include HFO-1234yf (CF3CF═CH2; tetrafluoropropene) and HFO-1234ze (CF3—CH═CHF). Note that, to be distinguished from HFC refrigerants, such as R32, not having a carbon double bond in their composition, HFC refrigerants having a carbon double bond are often referred to as “HFO” using “O” in olefin (unsaturated hydrocarbons having a carbon double bond are called olefins).
These low-GWP HFC refrigerants (including HFO refrigerants) are not as highly flammable as HC refrigerants such as the natural refrigerant R290 (C3H8; propane), but are slightly flammable, unlike the non-flammable R410A. Therefore, as in the case of R290, attention needs to be paid to refrigerant leakage. Hereinafter, refrigerants that are flammable, including even those slightly flammable, are referred to as “flammable refrigerants”.
In the case where a flammable refrigerant leaks into the indoor living space, the refrigerant concentration in the room increases and may reach a flammable concentration while the operation is stopped (while an indoor fan is not rotating). That is, a flammable concentration is not developed by slow leakage in cases such as when a pinhole is formed in a heat exchanger and when a flare joint is loose, because the leakage speed is low. However, a flammable concentration is likely to be developed by rapid leakage in cases such as when a connection portion between pipes is broken by an external force and when a flare joint comes off, because the leakage speed is high. Note that while the air-conditioning apparatus is in operation, even if the refrigerant leaks, the refrigerant concentration does not increase to a flammable concentration, because the indoor air is agitated and the leaked refrigerant is diffused.
In view of the above, there is disclosed a split type air-conditioning apparatus that includes a temperature sensor disposed at a position in a refrigerant circuit where liquid refrigerant is likely to accumulate, more specifically, at the lower part of a header of an indoor heat exchanger, and a refrigerant leakage determining unit, which determines that the refrigerant is leaking when the refrigerant temperature detected by the temperature sensor decreases at a speed higher than a predetermined speed while a compressor is stopped (see, for example, Patent Literature 1).
Patent Literature 1: Japanese Unexamined Patent Application Publication No. 2000-81258 (page 3, FIG. 2)
However, according to the split type air-conditioning apparatus disclosed in Patent Literature 1, the temperature sensor is disposed at a predetermined position in the refrigerant circuit, and a determination is made that the refrigerant is leaking if the temperature sensor detects a rapid reduction in temperature due to evaporation of the liquid refrigerant at the position where the temperature sensor is disposed. Therefore, there are the following problems.
(a) Since the refrigerant distribution in the refrigerant circuit is not always uniform while the refrigerant circuit is stopped, the liquid refrigerant does not always accumulate at the position where the temperature sensor is disposed. Therefore, in the case where the liquid refrigerant is not present, even when refrigerant leakage occurs, it is difficult to detect the occurrence of refrigerant leakage.
(b) Further, even if, after occurrence of refrigerant leakage, the liquid refrigerant moves to the position where the temperature sensor is disposed and a rapid reduction in temperature due to evaporation of the liquid refrigerant is detected, it is not possible to quickly detect the occurrence of refrigerant leakage because the movement of the liquid refrigerant takes time.
(c) Further, even if refrigerant leakage occurs when the liquid refrigerant is accumulated at the position where the temperature sensor is disposed, or even if the liquid refrigerant moves to the position where the temperature sensor is disposed after occurrence of refrigerant leakage, in the case where the amount of the accumulated liquid refrigerant or the amount of the liquid refrigerant having moved thereto is small, the refrigerant leakage may not be detected because the amount of temperature reduction (the amount of heat removal) is small.
(d) Further, since the temperature sensor is disposed in a pipe forming the refrigerant circuit or in a liquid storing part formed in a pipe, even if the temperature of the liquid refrigerant decreases rapidly, the occurrence of refrigerant leakage may not be detected quickly, or refrigerant leakage itself may not be detected, because a change in temperature that is detected by the temperature sensor is reduced due to the heat capacity (heat inertia) of the pipe or the liquid storing part.
The present invention has been made to overcome the above problems, and aims to provide an air-conditioning apparatus and a refrigerant leakage detection method capable of quickly and reliably detecting refrigerant leakage.
An air-conditioning apparatus according to the present invention includes an outdoor unit including at least a compressor and an outdoor pipe, an indoor unit including at least an indoor heat exchanger, an indoor fan, and an indoor pipe, an extension pipe connecting the outdoor pipe and the indoor pipe to each other, a first temperature sensor disposed under a connection portion connecting the indoor heat exchanger and the indoor pipe to each other, and a control unit configured to determine whether a refrigerant having a higher specific gravity than indoor air is leaking from the connection portion, on the basis of a change in a temperature detected by the first temperature sensor, while the indoor fan is stopped.
According to the present invention, the first temperature sensor is disposed under the connection portion connecting the heat exchanger and the indoor pipe to each other where refrigerant is likely to leak in a housing of the indoor unit. Therefore, if a refrigerant having a higher specific gravity than indoor air leaks from the connection portion, the first temperature sensor can directly detect a reduction in temperature of the atmosphere (leaked refrigerant itself; in some cases, ambient air is included) due to the vaporization heat (heat removal) at the time of adiabatic expansion of the leaked refrigerant. Thus, it is possible to quickly and accurately detect leakage of the refrigerant at an early stage of the occurrence of refrigerant leakage (at a time point when the cumulative amount of leakage is relatively low), without being affected by the heat capacity of the pipe or another related component.
In
Further, a control unit 1 is disposed in the indoor unit 101. As will be described below, the control unit 1 controls respective components and determines whether refrigerant is leaking.
(Refrigerant Circuit of Outdoor Unit)
The outdoor unit 102 includes a compressor 3 that compresses and discharges refrigerant, a refrigerant flow switching valve (hereinafter referred to as a “four-way valve”) 4 that changes the flow direction of the refrigerant in the refrigerant circuit on switching between a cooling operation and a heating operation, an outdoor heat exchanger 5 as a heat-source-side heat exchanger that exchanges heat between the outdoor air and the refrigerant, and a pressure reducing device (hereinafter referred to as an expansion valve) 6 as an expanding unit, such as an electronically-controlled expansion valve, that has a variable opening degree and reduces the pressure of high-pressure refrigerant to a low pressure. These components are connected to each other by an outdoor pipe (i.e., a heat-source-side refrigerant pipe) 8.
Further, an outdoor fan 5f that supplies (blows) the outdoor air to the outdoor heat exchanger 5 is disposed to face the outdoor heat exchanger 5. An air flow that passes through the outdoor heat exchanger 5 is generated by rotating the outdoor fan 5f. In the outdoor unit 102, a propeller fan is used as the outdoor fan 5f, and the outdoor air is suctioned through the outdoor heat exchanger 5. The outdoor heat exchanger 5 is disposed at the downstream side of the air flow generated by the outdoor fan 5f.
(Outdoor Pipe)
The outdoor pipe 8 includes an outdoor pipe 8a connecting an extension pipe connecting valve 13a at the gas side (during a cooling operation) to the four-way valve 4, a suction pipe 11 connecting the four-way valve 4 to the compressor 3, a discharge pipe 12 connecting the compressor 3 to the four-way valve 4, an outdoor pipe 8c connecting the four-way valve 4 to the outdoor heat exchanger 5, an outdoor pipe 8d connecting the outdoor heat exchanger 5 to the expansion valve 6, and an outdoor pipe 8b connecting the expansion valve 6 to an extension pipe connecting valve 13b at the liquid side (during a cooling operation). The outdoor pipe 8 collectively refers to these components.
(Extension Pipe Connecting Valve)
The gas-side extension pipe connecting valve 13a is disposed on the outdoor pipe 8 at the connection portion to the gas-side extension pipe 10a. On the other hand, the liquid-side extension pipe connecting valve 13b is disposed on the outdoor pipe 8 at the connection portion to the liquid-side extension pipe 10b.
The gas-side extension pipe connecting valve 13a is a two-way valve capable of switching between the open and closed states, and a flare joint 16a is attached to an end thereof.
The liquid-side extension pipe connecting valve 13b is a three-way valve capable of switching between the open and closed states, and a service port 14b to be used on vacuuming (on preparatory work for supplying refrigerant to the air-conditioning apparatus 100) and a flare joint 16b are attached thereto.
An external thread is processed on the outdoor-pipe-8-side of each of the flare joints 16a and 16b attached to the extension pipe connecting valves 13a and 13b (including the service port 14b). At the time of shipment of the outdoor unit 102 (including the time of shipment of the air-conditioning apparatus 100), a flare nut (not illustrated) having an internal thread processed therein that engages the external thread is attached thereon.
(Service Port)
For convenience of explanation below, a part of the outdoor pipe 8 connecting the compressor 3 to the inlet of the four-way valve 4 at the discharge side of the compressor 3 is referred to as the discharge pipe 12, and a part connecting the four-way valve 4 to the compressor 3 at the suction side of the compressor 3 is referred to as the suction pipe 11. Thus, during both a cooling operation (operation that supplies low-temperature low-pressure refrigerant to the indoor heat exchanger 7) and a heating operation (operation that supplies high-temperature high-pressure refrigerant to the indoor heat exchanger 7), high-temperature high-pressure gaseous refrigerant compressed by the compressor 3 always flows in the discharge pipe 12, and low-temperature low-pressure refrigerant after an evaporation action flows in the suction pipe 11.
The low-temperature low-pressure refrigerant flowing in the suction pipe 11 is sometimes gaseous refrigerant and sometimes in a two-phase state. A service port 14a with a flare joint attached thereto at the low-pressure side is disposed in the suction pipe 11, and a service port 14c with a flare joint attached thereto at the high-pressure side is disposed in the discharge pipe 12. On installation or a test operation at the time of repair, pressure gauges are connected to the service ports 14a and 14c so that the service ports 14a and 14c are used to measure the operating pressure.
Note that an external thread is made on each of the flare joints (not illustrated) of the service ports 14a and 14c. A flare nut (not illustrated) is attached on the external thread, at the time of shipment of the outdoor unit 102 (including the time of shipment of the air-conditioning apparatus 100).
(Refrigerant Circuit of Indoor Unit)
The indoor unit 101 includes an indoor heat exchanger 7 as a use-side heat exchanger that exchanges heat between the indoor air and the refrigerant. Indoor pipes (i.e., use-side refrigerant pipes) 9a and 9b are connected to the indoor heat exchanger 7 (the configuration of the indoor pipes 9a and 9b will be described separately in detail).
A flare joint 15a for connection to the gas-side extension pipe 10a is disposed on the indoor pipe 9a at the connection portion to the gas-side extension pipe 10a. On the other hand, a flare joint 15b for connection to the liquid-side extension pipe 10b is disposed on the indoor pipe 9b at the connection portion to the liquid-side extension pipe 10b.
An external thread is made on each of the flare joints 15a and 15b. A flare nut (not illustrated) having an internal thread processed therein that engages the external thread is attached thereon, at the time of shipment of the indoor unit 101 (including the time of shipment of the air-conditioning apparatus 100).
Further, an indoor fan 7f is disposed to face the indoor heat exchanger 7, and generates an air flow that passes through the indoor heat exchanger 7 by rotation of the indoor fan 7f. Note that the indoor fan 7f is driven by a non-brush motor (an induction motor or a DC brushless motor), and therefore does not generate sparks that may become the ignition source during operation. Further, various types of fans such as a cross-flow fan, a turbo fan may be used as the indoor fan 7f, depending on the form of the indoor unit 101. Further, the position of the indoor fan 7f may be either the downstream or the upstream of the indoor heat exchanger 7 in the air flow generated by the indoor fan 7f.
(Refrigerant Circuit of Air Conditioning Apparatus)
The gas-side extension pipe 10a has one end detachably connected to the flare joint 16a attached to the gas-side extension pipe connecting valve 13a of the outdoor unit 102, and has the other end detachably connected to the flare joint 15a attached to the indoor pipe 9a of the indoor unit 101. On the other hand, the liquid-side extension pipe 10b has one end detachably connected to the flare joint 16b attached to the liquid-side extension pipe connecting valve 13b of the outdoor unit 102, and has the other end detachably connected to the flare joint 15b attached to the indoor pipe 9b of the indoor unit 101.
That is, the outdoor pipe 8 is connected to the indoor pipes 9a and 9b by the extension pipes 10a and 10b so that a refrigerant circuit is formed, and a compression heat pump cycle that circulates the refrigerant compressed by the compressor 3 is formed.
(Flow of Refrigerant During Cooling Operation)
In
The outdoor heat exchanger 5 functions as a condenser. That is, when an air flow generated by rotation of the outdoor fan 5f passes through the outdoor heat exchanger 5, the outdoor air passing therethrough and the refrigerant flowing in the outdoor heat exchanger 5 exchange heat, so that condensation heat of the refrigerant is applied to the outdoor air. Thus, the refrigerant is condensed to become liquid refrigerant in the outdoor heat exchanger 5.
Then, the liquid refrigerant flows into the expansion valve 6. In the expansion valve 6, the liquid refrigerant is adiabatically expanded to become low-pressure low-temperature two-phase refrigerant.
Subsequently, the low-pressure low-temperature two-phase refrigerant is supplied to the indoor unit 101 through the extension pipe 10b and the indoor pipe 9b at the liquid side, and flows into the indoor heat exchanger 7. This indoor heat exchanger 7 functions as an evaporator. That is, when the flow of indoor air generated by rotation of the indoor fan 7f passes through the indoor heat exchanger 7, the indoor air passing therethrough and the refrigerant flowing in the indoor heat exchanger 7 exchange heat. Thus, the refrigerant evaporates to turn into low-temperature low-pressure gaseous refrigerant or two-phase refrigerant, by taking evaporation heat (heating energy) from the indoor air. On the other hand, the indoor air passing therethrough is cooled by taking cooling energy from the refrigerant, and cools the room.
Further, the refrigerant that has evaporated to turn into of low-temperature low-pressure gaseous refrigerant or two-phase refrigerant in the indoor heat exchanger 7 is supplied to the outdoor unit 102 through the indoor pipe 9a and the extension pipe 10a at the gas side, and is suctioned into the compressor 3 via the four-way valve 4. Then, the refrigerant is again compressed to turn into high-temperature high-pressure gaseous refrigerant in the compressor 3. This cycle is repeated during the cooling operation.
(Flow of Refrigerant During Heating Operation)
In
(Refrigerant)
In the air-conditioning apparatus 100, R32 (CH2F2; difluoromethane) is used as a refrigerant flowing in the refrigerant circuit. R32 is an HFC refrigerant that has a lower GWP than R410A, which is the HFC refrigerant that is currently and commonly used in air conditioning apparatuses. R32 has a relatively low impact on global warming, but is slightly flammable. The outdoor unit 102 is shipped with a certain amount of refrigerant sealed therein in advance. On installing the air-conditioning apparatus 100, if refrigerant is not enough for the length of the extension pipes 10a and 10b, refrigerant is added on site. Alternatively, the outdoor unit 102 may be shipped with no refrigerant sealed therein, and the full amount of refrigerant may be charged (sealed) on site.
Note that the refrigerant is not limited to R32, and may be any of the above described HFO refrigerants, such as HFO-1234yf (CF3CF═CH2; tetrafluoropropene) and HFO-1234ze (CF3—CH═CHF), which are slightly flammable, similar to R32; which are halogenated hydrocarbons that are a type of HFC refrigerant but have a carbon double bond in their composition; and which have a lower GWP than R32.
Further, the refrigerant may be a highly flammable HC refrigerant such as R290 (C3H8; propane) and R1270 (C3H6; propylene). Further, the refrigerant may be a mixed refrigerant as a mixture of two or more of these refrigerants.
(Configuration of Indoor Unit)
In
Note that the size and shape of the air inlet 112 and the air outlet 113 are not limited to those illustrated in
In
The indoor heat exchanger 7 is inclined in the upper space so that the upper end is located close to the housing rear surface 115 and the lower end is located close to the housing front surface 111. The communication opening 21 of the partition plate 20 is located within a range where the indoor heat exchanger 7 is projected vertically downward.
That is, the indoor fan 7f suctions the indoor air in the lower space from the air inlet 112, and supplies the indoor air to the indoor heat exchanger 7 in the upper space through the communication opening 21. Then, the indoor air having exchanged heat in the indoor heat exchanger 7 becomes “conditioned air” and is blown into the room through the air outlet 113.
Note that, as mentioned above, the indoor fan 7f is driven by a non-brush motor (an induction motor or a DC brushless motor), and therefore does not generate sparks that may become the ignition source during operation.
(Connection Between Indoor Exchanger and Indoor Pipe)
In
Each of the heat-transfer pipes 71 includes a plurality of U-shaped pipes (hereinafter referred to as “hairpins”) 72 each having long straight pipe portions, and arc-shaped U-bends 73 each having short straight pipe portions allowing communications between the plurality of hairpins 72. The hairpins 72 and the U-bends 73 are connected to each other at connection portions (hereinafter referred to as “brazed portions W”, and indicated by black circles in
The gas-side indoor pipe 9a is connected to a cylindrical header main pipe 91a. The header main pipe 91a is connected to a plurality of header branch pipes 92a. The header branch pipes 92a are connected to first ends 71a of the heat-transfer pipes 71 (i.e., the hairpins 72).
Further, the liquid-side (two-phase-side) indoor pipe 9b is connected to a plurality of indoor refrigerant branch pipes 92b to be divided into a plurality of branches. Further, the header branch pipes 92a are connected to second ends 71b of the heat-transfer pipes 71 (i.e., the hairpins 72).
The connection between the header main pipe 91a and the header branch pipes 92a, the connection between the header branch pipes 92a and the ends 71a, the connection between the indoor pipe 9b and the indoor refrigerant branch pipes 92b, and the connection between the indoor refrigerant branch pipes 92b and the ends 71b are all made at brazed portions W (indicated by black circles in
(First Leaked Refrigerant Receiver)
In
The first leaked refrigerant receiver 94 is a gutter covering the area vertically below the brazed portions W, and a first leaked refrigerant storing part 93 is formed at the lower end thereof. Thus, when the refrigerant (that has a higher specific gravity than the indoor air) leaks from the positions of the brazed portions W, the first leaked refrigerant receiver 94 receives the leaked refrigerant and causes the leaked refrigerant to flow into the first leaked refrigerant storing part 93.
Note that the shape of the first leaked refrigerant receiver 94 is not particularly limited. The first leaked refrigerant receiver 94 may be a relatively deep receiver having a rectangular cross section or an arcuate cross section, and having a notch or a through hole through which the hairpins 72 extend, or may be a relatively shallow receiver having a side edge that is in contact with or is in close proximity to the lower surfaces of the hairpins 72.
The first leaked refrigerant storing part 93 is designed to temporarily store the refrigerant having flowed therein along the first leaked refrigerant receiver 94, and the storage capacity is not limited. Thus, the lower end of the first leaked refrigerant receiver 94 may be closed, and thus the area close to the lower end of the first leaked refrigerant receiver 94 may be regarded as the first leaked refrigerant storing part 93, without especially providing the first leaked refrigerant storing part 93.
Note that although the indoor pipe 9a and the indoor pipe 9b extend through the first leaked refrigerant storing part 93, the indoor pipe 9a and the indoor pipe 9b may be bent to extend around the first leaked refrigerant storing part 93 so that the indoor pipe 9a and the indoor pipe 9b do not extend through the first leaked refrigerant storing part 93.
(Second Leaked Refrigerant Receiver)
A second leaked refrigerant receiver 95 is disposed vertically below the flare joint 15a and the flare joint 15b. The second leaked refrigerant receiver 95 is a box covering a certain area vertically below the flare joint 15a and the flare joint 15b. When the refrigerant (that has a higher specific gravity than the indoor air) leaks from the flare joint 15a or the flare joint 15b, the second leaked refrigerant receiver 95 receives the leaked refrigerant and stores a certain amount of the leaked refrigerant.
Note that although the extension pipe 10a and the extension pipe 10b extend through the second leaked refrigerant receiver 95, the extension pipe 10a and the extension pipe 10b may be bent to extend around the second leaked refrigerant receiver 95 so that the extension pipe 10a and the extension pipe 10b do not extend through the second leaked refrigerant receiver 95.
(Temperature Sensor)
A temperature sensor (hereinafter referred to as an “inlet temperature sensor”) S1 that measures the temperature of the inlet air (i.e., the indoor air) during operation is disposed at the suction side (between the air inlet 112 and the indoor fan 7f) of the indoor fan 7f.
Further, a temperature sensor (hereinafter referred to as a “liquid pipe sensor”) S2 and a temperature sensor (hereinafter referred to as a “two-phase pipe sensor”) S3 are disposed in the indoor heat exchanger 7. The liquid pipe sensor S2 measures the temperature of the refrigerant flowing into the indoor heat exchanger 7 during a cooling operation, and measures the temperature of the refrigerant flowing out of the indoor heat exchanger 7 during a heating operation. The two-phase pipe sensor S3 is located at the substantial center of the indoor heat exchanger 7, and measures the evaporating temperature or the condensing temperature of the refrigerant.
Then, each of the temperatures detected by the inlet temperature sensor S1, the liquid pipe sensor S2, and the two-phase pipe sensor S3 is input to the control unit 1, and is used for controlling the operations of the compressor 3 and other related functions.
Further, a temperature sensor (hereinafter referred to as a “first temperature sensor”) S4 is disposed in the first leaked refrigerant receiver 94 (more precisely, the first leaked refrigerant storing part 93), and a temperature sensor (hereinafter referred to as a “second temperature sensor”) S5 is disposed in the second leaked refrigerant receiver 95.
That is, because the refrigerant may leak from the connection portions formed by the brazed portions W due to aging or an external force such as earthquake, if the refrigerant leaks, the first leaked refrigerant receiver 94 receives the leaked refrigerant having a higher specific gravity than the indoor air, and the first temperature sensor S4 detects a reduction in temperature of the atmosphere that is cooled by heat removal due to the vaporization heat of the leaked refrigerant.
Since the first leaked refrigerant storing part 93 that stores a certain amount of leaked refrigerant is provided and the first temperature sensor S4 is provided therein, it is possible to detect a reduction in temperature of the atmosphere temperature (ambient air) due to the vaporization heat of the leaked refrigerant at an early stage, and thus to detect refrigerant leakage early and reliably.
Note that in the present invention, it suffices to provide the first temperature sensor S4 at the upper side of the partition plate 20, without providing the first leaked refrigerant receiver 94. That is, the leaked refrigerant falls from a pinhole or another related component, and remains on the partition plate 20 in the case where the first leaked refrigerant receiver 94 is not provided. Therefore, by installing the first temperature sensor S4 at a position close to the partition plate 20, it is possible to detect a reduction in temperature of the ambient air due to the vaporization heat of refrigerant leakage.
Further, the refrigerant may also leak from the connection portions formed by the flare joints 15a and 15b due to aging or an external force such as earthquake. Therefore, by providing the second leaked refrigerant receiver 95 that receives and stores the refrigerant (that has a higher specific gravity than the indoor air) leaked from the flare joint 15a or the flare joint 15b, and by providing the second temperature sensor S5 therein, it is possible to detect refrigerant leakage early and reliably.
Note that since the refrigerant (that has a higher specific gravity than the indoor air) leaked from the flare joint 15a or the flare joint 15b falls and remains on the housing bottom surface 116 of the housing 110, the second temperature sensor S5 may be installed at a position close to the housing bottom surface 116, without providing the second leaked refrigerant receiver 95.
Further, since the temperature of the air in the area below the partition plate 20 in the housing 110 reduces due to vaporization of the refrigerant (that has a higher specific gravity than the indoor air) leaked from the flare joint 15a or the flare joint 15b, the second leaked refrigerant receiver 95 and the second temperature sensor S5 may be removed, a temperature detection by the inlet temperature sensor S1 may be performed while the operation is performed and while the operation is stopped, and the function of the second temperature sensor S5 may be added to the inlet temperature sensor S1 (i.e., the function of the inlet temperature sensor S1 is added to the second temperature sensor S5).
In
In
(Control of Refrigeration Cycle)
The control unit 1 controls the refrigeration cycle (the compressor 3, the expansion valve 6, and other components) on the basis of the values detected by the inlet temperature sensor S1, the liquid pipe sensor S2, and the two-phase pipe sensor S3.
Note that the positions where the liquid pipe sensor S2 and the two-phase pipe sensor S3 are not limited to the positions illustrated in the drawings.
In
In the case where the refrigerant leaks while the air-conditioning apparatus 100 is in operation (while the indoor fan 7f is rotating), since the air in the room is stirred by the conditioned air that is blown out, an area with a high concentration of leaked refrigerant is not formed in the room (not illustrated). On the other hand, in the case where the refrigerant leaks while the air-conditioning apparatus 100 is stopped (while the indoor fan 7f is not rotating), an area with a high concentration of leaked refrigerant is likely to be formed in the room.
Thus, in the air-conditioning apparatus 100, only while the operation is stopped (while the indoor fan 7f is not rotating) (Step 1), the first temperature sensor S4 and the second temperature sensor S5 detect temperatures (Step 2). Then, the first temperature sensor S4 and the second temperature sensor S5 detect temperatures at certain time intervals. If, in even one of the first temperature sensor S4 and the second temperature sensor S5, the amount of change in the detected temperature is greater than a certain threshold (for example, the difference between the previous detection value and the current detection value is 5 degrees C.) or the rate of change in the detected temperature is greater than a certain threshold (for example, 5 degrees C./minute) when the detected temperature decreases, the control unit 1 determines that the refrigerant is leaking (Step 3).
(Operation after Detection of Refrigerant Leakage)
When the refrigerant is determined to be leaking while the operation is stopped, the control unit 1 of the air-conditioning apparatus 100 starts rotation of the indoor fan 7f to stir the air in the room (Step 4).
Further, a notifying unit (the operation display unit 2, a non-illustrated sound generating unit, or another related component) disposed in the main body of the indoor unit 101 issues a notification such as “Refrigerant is leaking, please open the window” (Step 5).
Note that execution of Step 5 may be omitted.
(Advantageous Effects)
That is, the refrigerant leaked from the flare joint 15a rapidly adiabatically expands. Thus, while the refrigerant is taking the heating energy from the surroundings, the refrigerant falls due to its specific gravity being higher than that of the indoor air and flows into the second leaked refrigerant receiver 95. Thus, the ambient temperature, especially the atmosphere temperature of the second leaked refrigerant receiver 95, decreases rapidly, and therefore the temperature detected by the second temperature sensor S5 decreases rapidly immediately after the start of the leakage.
Meanwhile, the temperature detected by the inlet temperature sensor S1 also decreases rapidly immediately after the start of the leakage, although not as greatly as that detected by the second temperature sensor S5. This is because the temperature in the lower area of the housing 110 is reduced due to adiabatic expansion of the leaked refrigerant that does not yet flow into the second leaked refrigerant receiver 95 or adiabatic expansion of the leaked refrigerant that did not flow into the second leaked refrigerant receiver 95.
As is obvious from the experimental results described above, the refrigerant leakage detection method used in the air-conditioning apparatus 100 has the following remarkable advantageous effects.
(i) The atmosphere temperature (the refrigerant temperature or the air temperature) at a position where refrigerant leakage may occur is directly detected, and a determination is made that the refrigerant is leaking, on the basis of the state of change (reduction) in the detected temperature. Therefore, it is possible to make a determination accurately and quickly.
(ii) That is, no influence is exerted by the state of distribution of the refrigerant in the refrigerant circuit while the operation is stopped, or by the state of movement of the refrigerant in the refrigerant circuit after occurrence of refrigerant leakage, and therefore the problems with the split type air-conditioning apparatus disclosed in Patent Literature 1 are solved.
(iii) Further, since the atmosphere temperature directly cooled by heat removal associated with evaporation of the leaked refrigerant is detected, the detection sensitivity is not reduced due to the heat capacity (heat inertia) of the members such as pipes.
(iv) Further, since the first leaked refrigerant receiver 94 and the second leaked refrigerant receiver 95 are provided, the leaked refrigerant (in some cases, the air cooled by heat removal due to adiabatic expansion of the leaked refrigerant is included) reaches the areas around the first temperature sensor S4 and the second temperature sensor S5 more certainly.
(v) Note that in the case where the second temperature sensor S5 is removed and the inlet temperature sensor S1 is used to detect refrigerant leakage, the number of components is reduced, and the production cost is reduced.
(vi) Further, in the case where a determination is made that the refrigerant is leaking while the operation is stopped, rotation of the indoor fan 7f is started to stir the air in the room. Therefore, it is possible to reduce formation of an area with a high concentration of leaked refrigerant in the room. Further, since the notifying unit issues a notification of the leakage of the refrigerant to prompt the user to give ventilation or take other measures, it is possible to reduce formation of an area with a high concentration of leaked refrigerant in the room.
Note that in the above description, although the first leaked refrigerant receiver 94 and the second leaked refrigerant receiver 95 are provided, and the first temperature sensor S4 and the second temperature sensor S5 are disposed therein, respectively, the present invention is not limited thereto. For example, an opening communicating with the second leaked refrigerant receiver 95 may be formed in each of the first leaked refrigerant receiver 94 and the partition plate 20, and thus the provision of the first temperature sensor S4 may be omitted. In this case, by placing the second leaked refrigerant receiver 95 so that the upper edge thereof is in contact with or close to the partition plate 20, the flow of the leaked refrigerant into the area around the second temperature sensor S5 is further promoted.
In
That is, when the refrigerant (that has a higher specific gravity than the indoor air) leaks from a flare joint 15a or a flare joint 15b, the refrigerant is guided by the third leaked refrigerant receiver 96 to flow into the area around the inlet temperature sensor S1. Thus, leakage of the refrigerant is determined on the basis of changes in the temperature detected by the inlet temperature sensor S1 that continuously performs temperature detection even while the operation is stopped. That is, a refrigerant leakage detection method used in the air-conditioning apparatus 200 is in accordance with Embodiment 2, and the second temperature sensor S5 in Embodiment 2 corresponds to the inlet temperature sensor S1.
Therefore, since the second temperature sensor S5 is not provided and thus the number of components is reduced, the production cost of the air-conditioning apparatus 200 is reduced.
Note that in the above description, although the first temperature sensor S4 is disposed in the first leaked refrigerant receiver 94, the present invention is not limited thereto. For example, an opening communicating with the third leaked refrigerant receiver 96 may be formed in each of a first leaked refrigerant receiver 94 and a partition plate 20, and thus the provision of the first temperature sensor S4 may be omitted (in this case, by placing the third leaked refrigerant receiver 96 so that the upper edge thereof is in contact with or close to the partition plate 20, the flow of the leaked refrigerant into the area around the inlet temperature sensor S1 is further promoted).
In
Further, an air inlet 312 is formed in a housing bottom surface 316 of the housing 310 close to a housing rear surface 315, and an air outlet 313 is provided in a housing front surface 311.
The indoor fan 7f is located at a position close to the housing rear surface 315. The indoor heat exchanger 7 is disposed to be inclined toward the corner between the housing front surface 311 and the housing top surface 314.
Note that indoor pipes 9a and 9b are connected to the indoor heat exchanger 7 in a position close to a housing right end surface 318. These connections are made in the same manner as in Embodiment 1 (brazed portions W, see
Further, a fourth leaked refrigerant receiver 97 is formed that covers the area vertically below the connection portions (the brazed portions W, see
Further, a temperature sensor (hereinafter referred to as a “third temperature sensor”) S6 is disposed at a position close to the lower end of the fourth leaked refrigerant receiver 97.
That is, if the refrigerant leaks from any of the positions of the brazed portions W or from the flare joint 15a or the flare joint 15b, the leaked refrigerant is received by the fourth leaked refrigerant receiver 97, and the atmosphere temperature around the third temperature sensor S6 changes rapidly. Further, a refrigerant leakage detection method used in the air-conditioning apparatus 300 is in accordance with Embodiment 2, and the first temperature sensor S4 and the second temperature sensor S5 in Embodiment 2 correspond to the third temperature sensor S6.
Thus, similarly to Embodiment 1 and Embodiment 2, it is possible to detect refrigerant leakage early.
Note that the location of the connection portions (the brazed portions W) between the indoor heat exchanger 7 and the indoor pipes 9a and 9b and the location of the flare joints 15a and 15b are away from each other (away from each other in the horizontal direction), a leaked refrigerant receiver and a temperature sensor may be provided in each of the locations.
In
The housing 410 is a box having a square cross section with chamfered corners, and a decorative grille 420 is detachably attached to a housing bottom surface 416. In the decorative grille 420, an air inlet 422 formed at the center, and air outlets 423 are formed at four positions around the air inlet 422. Further, the indoor fan 7f is installed at the center of the housing top surface 414, and an indoor heat exchanger 7 having a square ring shape is disposed to surround the indoor fan 7f. Thus, the indoor air suctioned by the indoor fan 7f from the air inlet 422 exchanges heat in the indoor heat exchanger 7, and is blown from the outside of the indoor heat exchanger 7 into the room (not illustrated) through the air outlets 423.
Flare joints 15a and 15b are disposed at one of the four corners of the housing 410, and the indoor heat exchanger 7 is connected to indoor pipes 9a and 9b at this corner. These connections are made in the same manner as in Embodiment 1 (brazed portions W, see
Further, similarly to Embodiment 4, a fourth leaked refrigerant receiver 97 is formed that covers the area vertically below the connection portions (the brazed portions W, see
Thus, similarly to the air-conditioning apparatus 200 (Embodiment 3), the air-conditioning apparatus 400 has the same advantageous effects as those of the air-conditioning apparatus 100 (Embodiment 1 and Embodiment 2).
In the above, the floor type (Embodiments 1 and 3), the ceiling suspended type (Embodiment 4), and the ceiling cassette type (Embodiment 5) have been described as those that implement Embodiment 2. However, it is possible to implement Embodiment 2 in a wall type indoor unit of an air conditioning apparatus as well, and the same advantageous effects are obtained.
Further, although the air-conditioning apparatuses 100 to 400 have been described above, the present invention is not limited thereto. For example, the present invention may include a refrigeration cycle apparatus including a water heater or another related component.
1 control unit 2 operation display unit 3 compressor 4 four-way valve 5 outdoor heat exchanger 5f outdoor fan 6 expansion valve 7 indoor heat exchanger 7f indoor fan 8 outdoor pipe 8a outdoor pipe 8b outdoor pipe 8c outdoor pipe 8d outdoor pipe 9a indoor pipe 9b indoor pipe 10a extension pipe 10b extension pipe 11 suction pipe 12 discharge pipe 13a extension pipe connecting valve 13b extension pipe connecting valve 14a service port 14b service port 14c service port 15a flare joint 15b flare joint 16a flare joint 16b flare joint 20 partition plate 21 communication opening 70 radiator plate 71 heat-transfer pipe 71a end 71b end 72 hairpin 73 U-bend 80 holder 81 pipe holding part 82 arm part 83 sensor holding part 91a header main pipe 92a header branch pipe 92b indoor refrigerant branch pipe 93 first leaked refrigerant storing part 94 first leaked refrigerant receiver 95 second leaked refrigerant receiver 96 third leaked refrigerant receiver 97 fourth leaked refrigerant receiver 100 air-conditioning apparatus 101 indoor unit 102 outdoor unit 110 housing 111 housing front surface 112 air inlet 113 air outlet 114 housing top surface 115 housing rear surface 116 housing bottom surface 200 air-conditioning apparatus 201 indoor unit 300 air-conditioning apparatus 301 indoor unit 310 housing 311 housing front surface 312 air inlet 313 air outlet 314 housing top surface 315 housing rear surface 316 housing bottom surface 318 housing right end surface 400 air-conditioning apparatus 401 indoor unit 410 housing 414 housing top surface 416 housing bottom surface 420 decorative grille 422 air inlet 423 air outlet S1 inlet temperature sensor S2 liquid pipe sensor S3 two-phase pipe sensor S4 first temperature sensor S5 second temperature sensor S6 third temperature sensor W brazed portion
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-174790 | Aug 2013 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2014/069972 | 7/29/2014 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2015/029678 | 3/5/2015 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4745765 | Pettitt | May 1988 | A |
| 4856288 | Weber | Aug 1989 | A |
| 5152152 | Brickner | Oct 1992 | A |
| 6330802 | Cummings | Dec 2001 | B1 |
| 20020178738 | Taira | Dec 2002 | A1 |
| 20040078974 | St. James | Apr 2004 | A1 |
| 20050039469 | Nonaka | Feb 2005 | A1 |
| 20050086952 | Nonaka | Apr 2005 | A1 |
| 20080202738 | Nelson | Aug 2008 | A1 |
| 20090094999 | Leatherbarrow | Apr 2009 | A1 |
| 20110000234 | Nishimura | Jan 2011 | A1 |
| 20110112814 | Clark | May 2011 | A1 |
| 20110174059 | Yonemori | Jul 2011 | A1 |
| 20110277541 | Kadle | Nov 2011 | A1 |
| 20120272672 | Morimoto | Nov 2012 | A1 |
| 20130087204 | Beard | Apr 2013 | A1 |
| 20130133359 | Ueda et al. | May 2013 | A1 |
| 20130180268 | Schlosser | Jul 2013 | A1 |
| 20150007591 | Liu | Jan 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| 204100499 | Jan 2015 | CN |
| 1 855 064 | Nov 2001 | EP |
| H04-369370 | Dec 1992 | JP |
| H11-142004 | May 1999 | JP |
| 2000-081258 | Mar 2000 | JP |
| 2000-146393 | May 2000 | JP |
| 2000-258000 | Sep 2000 | JP |
| 2002-103952 | Apr 2002 | JP |
| 2002-228281 | Aug 2002 | JP |
| 2004-286255 | Oct 2004 | JP |
| 2010-078285 | Apr 2010 | JP |
| 2011-247571 | Dec 2011 | JP |
| 2013-047591 | Mar 2013 | JP |
| 2013-113555 | Jun 2013 | JP |
| WO 2013119489 | Aug 2013 | WO |
| Entry |
|---|
| Office Action dated Sep. 26, 2016 issued in corresponding AU patent application No. 2014313328. |
| Extended European Search Report dated Feb. 27, 2017 issued in corresponding EP patent application No. 14840930.3. |
| Office Action dated Oct. 9, 2016 in the corresponding CN Patent application No. 201410424347.9 (and English translation). |
| International Search Report of the International Searching Authority dated Oct. 28, 2014 for the corresponding international application No. PCT/JP2014/069972 (and English translation). |
| Office Action dated Dec. 2, 2014 in the corresponding JP application No. 2013-174790 (with English translation). |
| Office Action dated May 7, 2015 in the corresponding JP application No. 2013-174790 (with English translation). |
| Office Action dated Sep. 1, 2017 issued in corresponding CN patent application No. 201410424347.9 (and English translation). |
| Office Action dated Apr. 19, 2017 issued in corresponding CN patent application No. 201410424347.9 (and partial English translation). |
| Office Action dated Feb. 20, 2019 issued in corresponding CN patent application No. 201410424347.9 (and English translation). |
| Office Action dated May 31, 2019 issued in corresponding MX patent application No. MX/a/20161002486 (and English translation). |
| Examination Report dated May 22, 2019 issued in corresponding IN patent application No. 201647007462 (and English translation). |
| Number | Date | Country | |
|---|---|---|---|
| 20160091241 A1 | Mar 2016 | US |
