The present invention relates to a control method for a refrigerated merchandiser. More specifically, the invention relates to a modular refrigerated display case.
Refrigerated merchandisers are used by grocers to store and display food items in a product display area that must be kept within a predetermined temperature range. These merchandisers generally include a case that is conditioned by a refrigeration system that has a compressor, a condenser, and at least one evaporator connected in series with each other. For open and closed merchandisers that have modular sections, the air temperature among the product display sections can fluctuate significantly. These temperature fluctuations can damage food product supported in the case.
In one construction, the invention provides a method of controlling a refrigerated merchandiser including a plurality of display case modules each having a separate refrigeration circuit with a compressor and an evaporator. The method includes selectively starting and stopping a first compressor of a first refrigeration circuit having a first evaporator associated with a first display case module to regulate a temperature in a product display area of the first display case module, and selectively starting and stopping a second compressor of a second refrigeration circuit having a second evaporator associated with a second display case module to regulate a temperature in a product display area of the second display case module. The method also includes controlling the first refrigeration module and the second refrigeration module based on a heat load of the merchandiser and a predetermined number of start/stop cycles of each of the first compressor and the second compressor within a given time period.
In another construction, the invention provides a method of controlling a refrigerated merchandiser including a plurality of display case modules each having a separate refrigeration circuit with a compressor and an evaporator. The method includes determining a temperature associated with a first product display area of a first display case module, selectively starting and stopping a first compressor of a first refrigeration circuit having a first evaporator associated with the first display case module to regulate the temperature associated with the first product display area, determining a temperature associated with a second product display area of a second display case module, and selectively starting and stopping a second compressor of a second refrigeration circuit having a second evaporator associated with the second display case module to regulate the temperature associated with the second product display area. The method also includes weighting a run time of one of the first compressor and the second compressor for a predetermined time interval based on the time-averaged temperatures of the first and second product display areas, and evenly regulating the temperatures of the first and second product display areas.
In another construction, the invention provides a method of controlling a refrigerated merchandiser including a plurality of display case modules each having a separate refrigeration circuit with a compressor and an evaporator. The method includes determining a temperature associated with a first product display area of a first display case module, selectively starting and stopping a first compressor of a first refrigeration circuit having a first evaporator associated with the first display case module to regulate the temperature associated with the first product display area, determining a temperature associated with a second product display area of a second display case module, and selectively starting and stopping a second compressor of a second refrigeration circuit having a second evaporator associated with the second display case module to regulate the temperature associated with the second product display area. The method also includes selectively weighting a run time of one of the first compressor and the second compressor for a predetermined time interval based on the time-averaged temperature of the first product display area and the time-averaged temperature of the second product display area, evenly regulating the temperatures of the first and second product display areas, and controlling the first refrigeration circuit and the second refrigeration circuit based on a heat load of the merchandiser and a predetermined number of start/stop cycles of each of the first compressor and the second compressor within a given time period.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
a is a table illustrating compressor operation for the refrigerated merchandiser of
b is a table illustrating compressor operation at 92% heat load in response to the display case modules having uniform time-averaged air temperatures.
c is a table illustrating compressor operation at 83% heat load in response to the display case modules having uniform time-averaged air temperatures.
d is a table illustrating compressor operation at 66% heat load in response to the display case modules having uniform time-averaged air temperatures.
a is a table illustrating compressor operation for the refrigerated merchandiser of
b is a table illustrating compressor operation at 75% heat load in response to one of the display case modules having a colder time-averaged air temperature than the remaining display case modules.
c is a table illustrating compressor operation at 66% heat load in response to one of the display case modules having a colder time-averaged air temperature than the remaining display case modules.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
With reference to
The merchandiser 10 has a heat load that correlates to the amount of heat that needs to be extracted from the product display areas 40 to maintain food product within a predetermined temperature range (e.g., 33-41° Fahrenheit). Generally, the merchandiser heat load is impacted by and will change depending on heat of food product and case structure in the product display area 40, and heat introduced from the surrounding environment. Other factors may also affect the merchandiser heat load.
Referring to
Each refrigeration circuit 45 has a compressor 50 (e.g., one compressor or several compressors 50 in an assembly), a gas cooler or condenser 55, an expansion valve 60, and an evaporator 65 fluidly coupled in series with each other. Each compressor 50 has a run time that increments whenever the compressor 50 is in an on state. Generally, each compressor 50 is cycled to an off state when the temperature in the associated product display area 40 is below a predetermined temperature range. Also, each compressor 50 has a predetermined number of start/stop cycles (e.g., 6 starts and stops of a compressor) that are allowed or permitted (e.g., by a manufacturer) within a given time period (e.g., one hour) to limit wear and tear on the compressor 50. The predetermined number of start/stop cycles can be determined by the permitted or allowed start/stop cycles for each compressor 50 based on manufacturer recommendations, or by other factors. The illustrated compressors 50 are fixed-speed compressors that are placed remote from the merchandiser 10, although the compressors 50 can take other forms and can be positioned in or adjacent the merchandiser 10, if desired.
As is known in the art, the evaporator 65 is fluidly coupled with the compressor 50 via a suction line to deliver evaporated refrigerant from the evaporator 65 to the compressor 50, and is fluidly coupled with the condenser 55 via the expansion valve 60 and an inlet line to receive cooled, condensed refrigerant from the condenser 55. Each evaporator 65 is in communication with air flowing within an air passageway (not shown) that extends through the associated display case module 20 so that the airflow is refrigerated by heat transfer with refrigerant in the evaporator 65. The conditioned airflow is directed toward the product display area 40 (e.g., typically in the form of an air curtain through the canopy 35, etc.) to maintain food product in the product display area 40 within the predetermined temperature range by removing the heat load. Although not shown, each refrigeration circuit 45 can include other components based on the desired characteristics for the merchandiser 10.
With continued reference to
In operation, the controller 80 controls operation of the compressors 50a-c and the evaporators 65a-c to regulate the temperatures in the product display areas 40a-c so that these temperatures are uniform or consistent with each other. Stated another way, it is desired to have the time-averaged temperature in each product display area 40 be substantially equal to each other so that food product in all the display case modules 20 is maintained within the predetermined temperature range. To accomplish this, the controller 80 selectively starts and stops each compressor 50 to regulate the temperature of the associated product display area 40.
In general, when the product display temperature drops below the predetermined temperature range, the controller 80 cycles the associated compressor 50 to the off state so that refrigeration of the air flowing through the display case module 20 is substantially suspended. As a result, the temperature in the product display area 40 slowly increases to within the predetermined temperature range. The controller 80 then starts the compressor 50 when additional refrigeration is needed to maintain the temperature of the product display area 40 within the predetermined temperature range.
The controller 80 uses the signals from the sensors 70a-c to determine the temperatures of the first, second, and third product display areas 40a-c, and over time, the controller 80 determines the time-averaged temperature for each product display area 40. The controller 80 also manages the refrigeration circuits 45a-c to control the run time the compressors 50a-c based on the time-averaged temperatures of the product display areas 40a-c, and to control the number of start/stop cycles of each compressor 50 within the given time period.
In some circumstances, one product display area 40 can have a time-averaged temperature that is colder than adjacent product display areas 40. Referring back to step 110, if the time-averaged temperatures of the product display areas 40a-c are not uniform (i.e., “No” at step 110), the control process continues to step 125. At step 125, the controller 80 manages the refrigeration circuits 45a-c so that one or more of the compressors 50a-c among the refrigeration circuits 45a-c are weighted to have a longer run time than at least one other compressor 50. The time-averaged temperature of the colder product display area 40 eventually increases over time to match the time-averaged temperature of the other product display areas 40 because the associated compressor is off more frequently than the other compressors 50. Mixing or co-mingling of air in the merchandiser 10 over time also helps to return all of the time-average temperatures to a state of uniformity. The control process then proceeds to step 120, at which the controller 80 controls the refrigeration circuits 45a-c, taking into account whether the time-averaged temperature of one or more product display areas 40a-c is colder than the other temperatures. The controller 80 also regulates the product display area temperatures based on the sensed temperatures and the merchandiser heat load without exceeding the predetermined number of compressor start/stop cycles.
a-d illustrate more specific examples of control of the merchandiser 10 when the time-averaged temperatures of the product display areas 40a-c are substantially equal or uniform. Based on the heat load of the merchandiser 10, the controller 80 selectively starts or stops one or more of the compressors 50a-c to accommodate the heat load and maintain the temperatures within the predetermined temperature range without exceeding the maximum number of start/stop cycles for each compressor 50. Although
As illustrated in
b illustrates control of the merchandiser 10 when the merchandiser heat load is 92% of the maximum load and the time-averaged temperatures of the three product display areas 40a-c are uniform. The controller 80 manages the refrigeration circuits 45a-c based on the merchandiser heat load by selectively and sequentially stopping each compressor 50 of the three refrigeration circuits 45a-c for a predetermined time. Because the time-averaged temperatures are uniform among the product display areas 40a-c, each compressor 50 has approximately the same run time for the entire time period. The controller 80 also limits the number of start/stop cycles for each compressor 50 so that the predetermined number of start/stop cycles is not exceeded by any compressor 50 within the given time period. As illustrated, the controller 80 stops each compressor 50 once (e.g., for one minute) during the control cycle to adjust the refrigeration output based on the heat load being lower than the maximum heat load. The illustrated cyclic control of the compressors 50a-c is patterned so that all three compressors 50a-c are in the on state for three minutes after one of the compressors 50a-c is cycled to the off state and before the next compressor 50 is cycled to the off state. In other constructions, cyclic control of the compressors 50a-c can be patterned differently or made random.
c illustrates control of the merchandiser 10 when the merchandiser heat load is 83% of the maximum load and the time-averaged temperatures of the three product display areas 40a-c are uniform. The controller 80 manages the refrigeration circuits 45a-c based on the merchandiser heat load by selectively and sequentially stopping each compressor 50 of the three refrigeration circuits 45a-c for a predetermined time. Because the time-averaged temperatures are uniform among the product display areas 40, each compressor 50 has approximately the same run time for the entire time period. The controller 80 also limits the number of start/stop cycles for each compressor 50 so that the predetermined number of start/stop cycles is not exceeded by any compressor 50 within the given time period. As illustrated, the controller 80 stops each compressor 50 twice (e.g., for one minute each time) during the control cycle to adjust the refrigeration output based on the heat load being lower than the maximum heat load. The illustrated cyclic control of the compressors 50a-c is patterned so that all three compressors 50a-c are in the on state for one minute after one of the compressors 50 is cycled to the off state and before the next compressor 50 is cycled to the off state. In other constructions, the cyclic control of the compressors 50a-c can be patterned differently or made random.
d illustrates control of the merchandiser 10 when the merchandiser heat load is 66% of the maximum load and the time-averaged temperatures of the three product display areas 40 are uniform. The controller 80 manages the refrigeration circuits 45a-c based on the merchandiser heat load by selectively and sequentially stopping each compressor 50 of the three refrigeration circuits 45a-c for a predetermined time. Because the time-averaged temperatures are uniform among the product display areas 40, each compressor 50 has approximately the same run time for the entire time period. The controller 80 also limits the number of start/stop cycles for each compressor 50 so that the predetermined number of start/stop cycles is not exceeded by any compressor 50 within the given time period. As illustrated, the controller 80 stops each compressor 50 for once (e.g., for two minutes) during the cycle to adjust the refrigeration output based on the heat load being lower than the maximum heat load. The illustrated cyclic control of the compressors 50a-c is patterned so that only two compressors 50 are in the on state at the same time. In other constructions, the cyclic control of the compressors 50a-c can be patterned differently or made random.
a-c illustrate more specific examples of control of the merchandiser 10 when the time-averaged temperatures across the product display areas 40a-c are unequal or non-uniform relative to each other (e.g., none or fewer than all time-averaged temperatures are substantially equal to each other). By way of example only,
a illustrates control of the merchandiser 10 when the merchandiser heat load is 89% of the maximum load and the time-averaged temperature of the second product display area 40b is lower than the time-averaged temperatures of the first and third product display areas 40a, c. As shown, the controller 80 selectively starts and stops only the second compressor 50b to accommodate the merchandiser heat load without exceeding the maximum number of start/stop cycles for the second compressor 50b. As a result, the second compressor 50b has a run time that is shorter than the run times of the first and third compressors 50a, c such that the stop cycles for the control process illustrated in
The second compressor 50b is started and stopped several times during the cycle so that the time-averaged temperature of the second product display area 40b rises when the second compressor 50b is stopped. The controller 80 manages the second refrigeration circuit 45b relative to the first and third refrigeration circuits 45a, c so that the time-averaged temperatures among the first, second, and third product display areas 40a-c eventually return to a state of uniformity. The illustrated cyclic control of the compressors 50a-c is patterned so that the second compressor 50b is stopped for a period of time (e.g., one or two minutes), and started and operating for a period of time (e.g., four minutes) before the second compressor 50b is stopped again. In other constructions, the cyclic control of the compressors 50a-c can be patterned differently or made random.
b illustrates control of the merchandiser 10 when the merchandiser heat load is 75% of the maximum load and the time-averaged temperature of the second product display area 40b is lower than the time-averaged temperatures of the first and third product display areas 40a, c. As shown, the controller 80 selectively starts and stops only the second compressor 50b to accommodate the merchandiser heat load without exceeding the maximum number of start/stop cycles for the second compressor 50b. As a result, the second compressor 50b has a run time that is shorter than the run times of the first and third compressors 50a, c such that the stop cycles for the control process illustrated in
As illustrated, the second compressor 50b is stopped for a longer period of time (e.g., three minutes) to accommodate the lower heat load relative to the control process for the merchandiser 10 with an 89% heat load. The control process illustrated in
c illustrates control of the merchandiser 10 when the merchandiser heat load is 66% of the maximum load and the time-averaged temperature of the second product display area 40b is lower than the time-averaged temperatures of the first and third product display areas 40a, c. Generally, the control process of
The controller 80 is in communication with the compressors 50 to selectively start and stop the compressors 50 to regulate the temperatures associated with the product display areas 40 based in part on the temperatures detected by the sensors 70 and the heat load of the merchandiser 10. The controller 80 also accounts for the predetermined number of compressor start/stop cycles that are allowed for each compressor 50 within a given time period (e.g., one hour) so that, when possible, all compressors 50 have the same or substantially the same run time to avoid excessive wear and tear excessive wear and tear on the compressors 50.
As one or both of the heat load and the condensing temperature associated with the merchandiser decrease, the cyclic, sequential control of the compressors 50 in a time proportional manner avoids excessive temperature swings and eliminates the need for speed controls (e.g., inverters) for individual compressors 50. The control system 75 also accounts for situations in which one or more of the display case modules 20 have a time-averaged temperature that is lower than the time-averaged temperatures of the other display case modules 20 by regulating the compressor 50 associated with the display case module 20 with the lower time-averaged temperature. This way, the time-averaged temperatures across all display case modules 20 return to a uniform value within the predetermined temperature range. That is, the control process selectively weights the run time of the compressors 50 over a predetermined time interval based on the time-averaged temperatures and the heat load to more evenly regulate the time-averaged temperatures among the display case modules 20 without wearing out the compressors 50. Moreover, because the control process selectively starts and stops each compressor 50, defrost of each display case module 20 can be accomplished simply by stopping the associated compressor 50 at set times without having to modify the status of the other refrigeration circuits 45.
Various features and advantages of the invention are set forth in the following claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4152902 | Lush | May 1979 | A |
| 4614089 | Dorsey | Sep 1986 | A |
| 4748820 | Shaw | Jun 1988 | A |
| 5065591 | Shaw | Nov 1991 | A |
| 5123256 | Oltman | Jun 1992 | A |
| 5231846 | Goshaw et al. | Aug 1993 | A |
| 5343384 | Fisher et al. | Aug 1994 | A |
| 5586444 | Fung | Dec 1996 | A |
| 5743098 | Behr | Apr 1998 | A |
| 6233954 | Mehaffey et al. | May 2001 | B1 |
| 6568197 | Uno et al. | May 2003 | B2 |
| 6705097 | So et al. | Mar 2004 | B2 |
| 7159413 | Dail | Jan 2007 | B2 |
| 7540164 | Roche et al. | Jun 2009 | B2 |
| 7555913 | Hwang et al. | Jul 2009 | B2 |
| 7617695 | Shapiro | Nov 2009 | B2 |
| 7793509 | Crane | Sep 2010 | B2 |
| 8020391 | Swofford et al. | Sep 2011 | B2 |
| 20040031280 | Martin et al. | Feb 2004 | A1 |
| 20040261429 | Dobmeier et al. | Dec 2004 | A1 |
| 20050126193 | Lifson et al. | Jun 2005 | A1 |
| 20050126196 | Grassmuck et al. | Jun 2005 | A1 |
| 20060201175 | Shapiro et al. | Sep 2006 | A1 |
| 20080148751 | Swofford | Jun 2008 | A1 |
| 20110265507 | Zangari et al. | Nov 2011 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20140123691 A1 | May 2014 | US |