Patent Application
20170097005
Field of the Invention
The present invention generally relates to a centrifugal compressor. More specifically, the present invention relates to a centrifugal compressor with surge control.
Background Information
A chiller system is a refrigerating machine or apparatus that removes heat from a medium. Commonly a liquid such as water is used as the medium and the chiller system operates in a vapor-compression refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool air or equipment as required. As a necessary byproduct, refrigeration creates waste heat that must be exhausted to ambient or, for greater efficiency, recovered for heating purposes. A conventional chiller system often utilizes a centrifugal compressor, which is often referred to as a turbo compressor. Thus, such chiller systems can be referred to as turbo chillers. Alternatively, other types of compressors, e.g. a screw compressor, can be utilized.
In a conventional (turbo) chiller, refrigerant is compressed in the centrifugal compressor and sent to a heat exchanger in which heat exchange occurs between the refrigerant and a heat exchange medium (liquid). This heat exchanger is referred to as a condenser because the refrigerant condenses in this heat exchanger. As a result, heat is transferred to the medium (liquid) so that the medium is heated. Refrigerant exiting the condenser is expanded by an expansion valve and sent to another heat exchanger in which heat exchange occurs between the refrigerant and a heat exchange medium (liquid). This heat exchanger is referred to as an evaporator because refrigerant is heated (evaporated) in this heat exchanger. As a result, heat is transferred from the medium (liquid) to the refrigerant, and the liquid is chilled. The refrigerant from the evaporator is then returned to the centrifugal compressor and the cycle is repeated. The liquid utilized is often water.
A conventional centrifugal compressor basically includes a casing, an inlet guide vane, an impeller, a diffuser, a motor, various sensors and a controller. Refrigerant flows in order through the inlet guide vane, the impeller and the diffuser. Thus, the inlet guide vane is coupled to a gas intake port of the centrifugal compressor while the diffuser is coupled to a gas outlet port of the impeller. The inlet guide vane controls the flow rate of refrigerant gas into the impeller. The impeller increases the velocity of refrigerant gas, generally without changing pressure. The diffuser increases the refrigerant pressure without changing the velocity. The motor rotates the impeller. The controller controls the motor, the inlet guide vane and the expansion valve. In this manner, the refrigerant is compressed in a conventional centrifugal compressor. The inlet guide vane is typically adjustable and the motor speed is typically adjustable to adjust the capacity of the system. In addition, the diffuser may be adjustable to further adjust the capacity of the system. The controller controls the motor, the inlet guide vane and the expansion valve. The controller can further control any additional controllable elements such as the diffuser.
When the pressure behind the compressor is higher than the compressor outlet pressure, the fluid tends to reverse or even flow back in the compressor. As a consequence, the pressure will decrease, inlet pressure will increase and the flow reverses again. This phenomenon, called surge, repeats and occurs in cycles. The compressor loses the ability to maintain the peak head when surge occurs and the entire system becomes unstable. A collection of surge points during varying compressor speed or varying inlet guide vane angle is called a surge line. In normal conditions, the compressor operates in the right side of the surge line. However, during startup/emergency shutdown, the operating point will move towards the surge line because flow is reduced. If conditions are such that the operating point approaches the surge line, flow recirculation occurs in the impeller and diffuser. The flow recirculation, which causes flow separation, will eventually cause a decrease in the discharge pressure, and flow from suction to discharge will resume. Surging can cause the compressor to overheat to the point at which the maximum allowable temperature of the unit is exceeded. Also, surging can cause damage to the thrust bearing due to the rotor shifting back and forth from the active to the inactive side. This is defined as the surge cycle of the compressor.
Therefore, techniques have been developed to control surge. See for example, Japanese Patent Publication No. 5-263796.
In a conventional centrifugal compressor, when surge is predicted by the above technique or any other known technique, a compressor controller can control various parts to control surge. For example, the inlet guide vane and/or the discharge diffuser vane can be controlled or the speed of the compressor can be increased to control surge. While these techniques work relatively well, these systems can require additional components, and thus, increased costs. In addition, these techniques can reduce performance of the compressor.
Therefore, one object of the present invention is to provide a centrifugal compressor that controls surge without reducing performance.
Another object of the present invention is to provide a centrifugal compressor that controls surge without overly complicated construction and/or additional parts.
One or more of the above objects can basically be attained by providing a centrifugal compressor adapted to be used in a chiller, the centrifugal compressor including: a casing having an inlet portion and an outlet portion; an inlet guide vane disposed in the inlet portion; an impeller disposed downstream of the inlet guide vane, the impeller being rotatable about a rotation axis defining an axial direction, and the impeller being adjustably mounted within the casing along the axial direction between at least a first flow rate position and a second flow rate position; a motor arranged and configured to rotate the impeller; and a diffuser disposed in the outlet portion downstream from the impeller with a discharge port of the outlet portion being disposed between the impeller and the diffuser.
These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments.
Referring now to the attached drawings which form a part of this original disclosure:
Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
Referring initially to
Referring to
In the illustrated embodiment, the chiller system 10 predicts surge in a conventional manner. See for example U.S. Pat. No. 5,095,714. However, when surge is predicted, the chiller system 10 controls surge in accordance with the present invention. In particular, the controller 20 controls the current sent to the magnetic bearing assembly 40 to control an axial position of the impeller 34, as explained in more detail below.
Referring to
The magnetic bearing assembly 40 is preferably a combination of active magnetic bearings 44, 46, and 48, which utilizes non-contact position sensors 54, 56 and 58 to monitor shaft position and send signals indicative of shaft position to the magnetic bearing control section 61. Thus, each of the magnetic bearings 44, 46 and 48 are preferably active magnetic bearings. A magnetic bearing control section 61 uses this information to adjust the required current to a magnetic actuator to maintain proper rotor position both radially and axially. Active magnetic bearings are well known in the art, and thus, will not be explained and/or illustrated in detail herein, except as related to controlling surge in accordance with the present invention.
Referring to
Because the magnetic bearing control section 61 is connected to several portions of the magnetic bearing assembly 40 and communicates with various sections of the controller 20, the various sections of the controller 20 can receive signals from the sensors 54, 56 and 58 of the compressor 22, perform calculations and transmit control signals to parts of the compressor 22 such as the magnetic bearing assembly 40. Similarly, the various sections of the controller 20 can receive signals from the sensors S and T, perform calculations and transmit control signals to the compressor 22 (e.g., the motor) and the expansion valve 26. The control sections and the variable frequency drive 64 can be separate controllers or can be mere sections of the chiller controller programmed to execute the control of the parts described herein. In other words, it will be apparent to those skilled in the art from this disclosure that the precise number, location and/or structure of the control sections, control portion and/or controller 20 can be changed without departing from the present invention so long as the one or more controllers are programed to execute control of the parts of the chiller system 10 as explained herein.
The controller 20 is conventional, and thus, includes at least one microprocessor or CPU, an Input/output (I/O) interface, Random Access Memory (RAM), Read Only Memory (ROM), a storage device (either temporary or permanent) forming a computer readable medium programmed to execute one or more control programs to control the chiller system 10. The controller 20 may optionally include an input interface such as a keypad to receive inputs from a user and a display device used to display various parameters to a user. The parts and programming are conventional, except as related to controlling surge, and thus, will not be discussed in detail herein, except as needed to understand the embodiment(s).
The magnetic bearing control section 61 normally receives signals from the sensors 54, 56 and 58 of the magnetic bearing assembly 40, and transmits electrical signals to the magnetic bearings 44, 46 and 48 to maintain the shaft 42 in the desired position in a conventional manner. More specifically, the magnetic bearing control section 61 is programmed to execute a magnetic bearing control program to maintain the shaft 42 in the desired position in a conventional manner during normal operation when surge is not predicted. However, if surge is predicted, the axial position of the shaft 42 can be adjusted using the surge control section 62 and the axial magnetic bearing 48. Thus, the axial position of the impeller 34, which is fixed to the shaft 42, can be adjusted relative to the diffuser 36, as explained in more detail below.
The variable frequency drive 64 and motor control section 65 receive signals from at least one motor sensor (not shown) and control the rotation speed of the motor 38 to control the capacity of the compressor 22 in a conventional manner. More specifically, the variable frequency drive 64 and motor control section 65 are programmed to execute one or more motor control programs to control the rotation speed of the motor 38 to control the capacity of the compressor 22 in a conventional manner. The inlet guide vane control section 66 receives signals from at least one inlet guide vane sensor (not shown) and controls the position of the inlet guide vane 32 to control the capacity of the compressor 22 in a conventional manner. More specifically, the inlet guide vane control section 66 is programmed to execute an inlet guide vane control program to control the position of the inlet guide vane 32 to control the capacity of the compressor 22 in a conventional manner. The expansion valve control section 67 controls the opening degree of the expansion valve 26 to control the capacity of the chiller system 10 in a conventional manner. More specifically, the expansion valve control section 67 is programmed to execute an expansion valve control program to control the opening degree of the expansion valve 26 to control the capacity of the chiller system 10 in a conventional manner. The motor control section 65 and the inlet guide vane control section 66 work together and with the expansion valve control section 67 to control the overall capacity of the chiller system 10 in a conventional manner. The controller 20 receives signals from the sensors S and optionally T to control the overall capacity in a conventional manner. The optional sensors T are temperature sensors. The sensors S are preferably conventional pressure sensors and/or temperature sensors used in a conventional manner to perform the control.
Each the magnetic bearing 44 includes a plurality of actuators 74 and at least one amp 84. Similarly, each the magnetic bearing 46 includes a plurality of actuators 76 and at least one amplifier 86. Likewise, Each the magnetic bearing 48 includes a plurality of actuators 78 and at least one amp 88. The amplifiers 84, 86 and 88 of each magnetic bearing 44, 46, and 48 may be a multi-channel amp to control the number actuators thereof, or can include separate amplifiers for each actuator 74, 76 and 78. In either case, the amplifiers 84, 86 and 88 are electrically connected to the actuators 74, 76 and 78 of each respective magnetic bearing 44, 46, and 48.
Referring to
In the illustrated embodiment, the magnetic bearing 48 includes the thrust disk 45, two actuators 78 disposed on opposite sides of the thrust disk 45, two position sensors 58 disposed on opposite sides of the thrust disk 45, an amplifier 88 electrically connected to the two actuators 78, and the magnetic bearing control section 61. The magnetic bearing control section 61 is electrically connected to the amplifier 88, the position sensors 58, and the other portions of the controller 20. Each actuator 78 receives a respective current from the amplifier 88, and each current being determined by the magnetic bearing control section 61 and communicated to the amplifier 88 by a signal. The actuators 78 of the magnetic bearing 48 bias the thrust disk 45 to an axial position in which the net force of the two actuators 78 reach an equilibrium. During normal operation, the shaft 42 will be disposed at an axial position in which the flow rate is 100% as illustrated in
The magnetic bearing control section 61 of the present invention differs from a conventional magnetic bearing controller in that it is arranged to receive at least one external signal. The at least one external signal is an adjustment signal which indicates an adjustment to the desired axial position, which is needed in response to surge being predicted. The magnetic bearing control section 61 is programed to receive the adjustment signal and adjust the signal output to the amplifier 88 of the magnetic bearing 48 that indicates the amount of current to be supplied to the actuators 78 of magnetic bearing 48. In other words, the magnetic bearing control section 61 of the present invention will adjust the position of the shaft 42 in the axial direction based on an adjustment signal received.
The axial position of the impeller 34 relative to the inlet will determine the flow rate of the refrigerant and the velocity of the flow of refrigerant out of the impeller 34 when all other aspects of the chiller 10 remain constant. The flow rate of the refrigerant will also affect the capacity of the compressor 22. Because shaft 42 is shiftable to any point within the shiftable range of magnetic bearing 48, and the impeller 34 is attached to the shaft 42, the impeller 34 is also shiftable to an infinite number of positions in the axial direction. Each axial position of the impeller results in a unique flow rate and unique velocity. Thus, the flow rate and velocity of the refrigerant from the impeller 34 of the compressor may be infinitely adjusted.
The surge control section 63 is programmed to control surge upon receiving a signal from the surge prediction section 62. The signal from the surge prediction section 62 indicates that surge is predicted to occur. The surge prediction section 62 may predict surge in a conventional manner, such as those set forth in U.S. Pat. No. 5,095,714, or using any other technique without departing from the scope of this invention, as would be apparent in light of this disclosure. However, in the illustrated embodiment, the surge control section 63 controls surge by adjusting the axial position of the impeller 34 (moving the impeller toward the right in the views shown herein), i.e., from the 100% flow rate position shown in
The surge control section 63 is electrically connected to the bearing control section 61. The surge control section 63 sends an adjustment signal to the magnetic bearing control section 61 to control surge. More specifically, the surge control section 63 controls surge by shifting the shaft 42 in the axial direction. More specifically, the surge control section 63 is programmed to output an adjustment signal indicating an adjustment to the axial position of the impeller 34. The adjustment corresponds to a portion of the adjustable range. For example, each adjustment can be 5%, 10%, or 15% of the adjustable range. Thus, the surge control section 63 is programed to control surge by adjusting the flow rate of the compressor 22 which occurs when the impeller 34 is shifted in increments.
The surge control section 63 is programmed to adjust the axial position of the impeller 34 from a normal operating position (illustrated in
The surge control section 63 is programmed to determine the amount of adjustment of the position of impeller 34. The surge control section 63 is programmed to determine the amount of adjustment based on at least one operating parameter of the compressor 22. More specifically, the surge control section 63 is programmed to determine a target flow rate based on the predicted surge, as would be apparent in light of this disclosure. For example, the target flow rate may be determined based on at least one of the pressure of the refrigerant at the inlet of the impeller 34 and the pressure of the refrigerant within the diffuser. Once the surge control section 63 has determined the target flow rate, the surge control section 63 then calculates an adjustment to the axial position of the impeller 34 that would result in the target flow rate. The surge control section 63 then sends an adjustment signal to the magnetic bearing control section 61 indicating the adjustment to the axial position of the impeller 34. By non-limiting example, surge may be controlled by increasing velocity of the coolant. Increasing velocity of the coolant expands the operation range. Thus, the surge control section 63 may generate an adjustment signal corresponding to a portion of the adjustable range. For Example, each adjustment resulting from the adjustment signal can be 5%, 10%, or 15% of the adjustable range.
In response to the adjustment signal, the magnetic bearing control section 61 shifts the impeller in the axial direction from the normal operating position to the adjusted position. The normal operation position has a first flow rate, and an adjusted position has a second flow rate. By non-limiting example, the first flow rate is a peak flow rate (100%) of the compressor 22 as illustrated in
Referring to
The second flow rate and second velocity (the adjusted position of the impeller 34) may be determined according to several techniques. In one embodiment, the surge control section 63 may incrementally adjust the flow rate. For example, if the surge control section 63 receives a signal from the surge prediction section 62, the surge control section may adjust the flow rate by 5% by adjusting the position of the impeller 34. Should the surge prediction section 62 predict surge after the surge control section 63 has adjusted the flow rate by 5%, the surge control section 63 would adjust the flow rate by 10% by adjusting the position of the impeller 34. This cycle of incrementally adjusting the flow rate would continue until no surge is predicted by the surge prediction section 62, or the surge control section 63 has reached a maximum amount of adjustment.
Alternatively, the second flow rate and second velocity (the adjusted position of the impeller 34) may be determined by the surge control section 63 based on a predicted amount of surge. In other words, if surge prediction section 62 predicts a surge of amount X, the surge control section 63 may be programmed to determine an adjustment amount to account for a surge of amount X. Based on the adjustment amount to account for a surge of amount X, the surge control section can generate an adjustment signal based on the amount of adjustment, and adjust the position of the impeller 34.
Moreover, the second flow rate and second velocity (the adjusted position of the impeller 34) may be determined by the surge control section 63 based on a predetermined amount. For example, the amount of adjustment may be a static value, or based on a predetermined map. The surge control section 63 may default to a predetermined static adjustment amount during each instance the surge control section 63 receives a signal predicting surge and adjust the position of the impeller 34 to a predetermined position. Alternatively, the surge control section 63 may determine the amount of adjustment based on a predetermined map. The predetermined map may indicate an adjustment amount respective to a time or a duration which the surge prediction section 63 has predicted surge, and adjust the position of the impeller 34 to a position determined based on the predetermined map. Such a predetermined map is usually generated from experiments and programmed into the controller 20.
Conventionally, the inlet guide vane control section 66 controls the flow rate of refrigerant gas into the impeller by controlling the inlet guide vane 32. For example, the guide vane control section may determine a target capacity of the system, determine the amount of adjustment to the guide vane 32 necessary to reach the target capacity, and control the guide vane 32 to achieve the target capacity to control surge. However, an adjustable guide vane 32 increases the complexity of a conventional chiller system, and are a point of failure for conventional chiller systems so equipped. Likewise, some centrifugal compressors utilize an adjustable diffuser vane, which can be eliminated.
By controlling surge using the techniques described herein, the chiller system 10 is no longer limited to controlling surge via the inlet guide vane/guide vane control section, and/or an adjustable diffuser guide vane. In addition other adjustment structures may possibly be eliminated or made unnecessary. In other words, the diffuser may have no diffuser vanes (adjustable diffuser vanes) (not illustrated). Alternatively, the inlet guide vane may be fixed, and not adjustable (not illustrated). By foregoing the guide vane 32, the reliability of chiller system 10 may be increased, and the cost may be decreased.
Referring to
In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts.
The term “detect” as used herein to describe an operation or function carried out by a component, a section, a device or the like includes a component, a section, a device or the like that does not require physical detection, but rather includes determining, measuring, modeling, predicting or computing or the like to carry out the operation or function.
The term “configured” as used herein to describe a component, section or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function.
The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.
While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
