Electronic Expansion Valve

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

Some heating, ventilation, and/or air conditioning (HVAC) systems may comprise an electronic expansion valve (EEV) that regulates a flow of refrigerant entering a heat exchanger. The EEV may generally comprise a stepper motor which receives signals from an electronic controller to control the position of an obturator of an EEV. In some instances, however, the EEV may not be correctly calibrated.

SUMMARY

In some embodiments of the disclosure, an electronic expansion valve comprising a longitudinal displacement axis, a rotor comprising a magnet, a first sensor disposed along the longitudinal displacement axis at a first longitudinal location, and a second sensor disposed along the longitudinal displacement axis at a second longitudinal location, wherein the first longitudinal location is longitudinally offset from the second longitudinal location along the longitudinal displacement axis is disclosed.

In other embodiments of the disclosure, a heating, ventilation, and air conditioning system comprising an electronic expansion valve comprising a longitudinal displacement axis, a rotor comprising a magnet, a first sensor disposed along the longitudinal displacement axis at a first longitudinal location, and a second sensor disposed along the longitudinal displacement axis at a second longitudinal location, wherein the first longitudinal location is longitudinally offset from the second longitudinal location along the longitudinal displacement axis, and an electronic expansion valve controller is disclosed.

In yet other embodiments of the disclosure, a method of operating an electronic expansion valve comprising: providing an electronic expansion valve comprising a longitudinal displacement axis, a rotor comprising a magnet, an obturator, a first sensor disposed along the longitudinal displacement axis at a first longitudinal location, and a second sensor disposed along the longitudinal displacement axis at a second longitudinal location, wherein the first longitudinal location is longitudinally offset from the second longitudinal location along the longitudinal displacement axis, sensing the position of the obturator within the electronic expansion valve by the first sensor at the first longitudinal location and the second sensor at the second longitudinal location, outputting a first voltage from the first sensor to an electronic expansion valve controller, and outputting a second voltage from the second sensor to an electronic expansion valve controller is disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description:

FIG. 1 is simplified schematic diagram of an HVAC system according to an embodiment of the disclosure;

FIG. 2 is a simplified schematic diagram of the air circulation paths of the HVAC system of FIG. 1;

FIG. 3 is a cutaway view of an electronic expansion valve at a metering position according to an embodiment of the disclosure;

FIG. 4 is a cutaway view of an electronic expansion valve at a fully open position according to an embodiment of the disclosure;

FIG. 5 is a cutaway view of an electronic expansion valve at a fully closed position according to an embodiment of the disclosure;

FIG. 6 is a cutaway view of an electronic expansion valve at a fully open position according to an embodiment of the disclosure;

FIG. 7 is a cutaway view of an electronic expansion valve at a fully open position according to an embodiment of the disclosure;

FIG. 8 is a cutaway view of an electronic expansion valve at a fully open position according to an embodiment of the disclosure; and

FIG. 9 is a partial cutaway view of an electronic expansion valve at a fully open position according to an embodiment of the disclosure.

DETAILED DESCRIPTION

In some instances, it may be desirable to provide an electronic expansion valve (EEV) that is capable of more accurate control and monitoring. For example, where an EEV is not correctly calibrated, it may be desirable to utilize an EEV that comprises internal Hall Effect sensors to more accurately monitor and control the position of the obturator of an EEV. In other instances, it may also be desirable to instantaneously determine and verify the position and direction of movement of the obturator of an EEV. In some embodiments of the disclosure, systems and methods are disclosed that comprise providing an EEV that comprises a plurality of Hall Effect sensors that are longitudinally displaced along an axis of movement of the EEV and configured to detect the position and movement of the obturator of an EEV.

Referring now to FIG. 1, a simplified schematic diagram of an HVAC system 100 according to an embodiment of this disclosure is shown. HVAC system 100 comprises an indoor unit 102, an outdoor unit 104, and a system controller 106. In some embodiments, the system controller 106 may operate to control operation of the indoor unit 102 and/or the outdoor unit 104. As shown, the HVAC system 100 is a so-called heat pump system that may be selectively operated to implement one or more substantially closed thermodynamic refrigeration cycles to provide a cooling functionality and/or a heating functionality.

Indoor unit 102 comprises an indoor heat exchanger 108, an indoor fan 110, and an electronic expansion valve (EEV) 112. Indoor heat exchanger 108 is a plate fin heat exchanger configured to allow heat exchange between refrigerant carried within internal tubing of the indoor heat exchanger 108 and fluids that contact the indoor heat exchanger 108 but that are kept segregated from the refrigerant. In other embodiments, indoor heat exchanger 108 may comprise a spine fin heat exchanger, a microchannel heat exchanger, or any other suitable type of heat exchanger.

The indoor fan 110 is a centrifugal blower comprising a blower housing, a blower impeller at least partially disposed within the blower housing, and a blower motor configured to selectively rotate the blower impeller. In other embodiments, the indoor fan 110 may comprise a mixed-flow fan and/or any other suitable type of fan. The indoor fan 110 is configured as a modulating and/or variable speed fan capable of being operated at many speeds over one or more ranges of speeds. In other embodiments, the indoor fan 110 may be configured as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different ones of multiple electromagnetic windings of a motor of the indoor fan 110. In yet other embodiments, the indoor fan 110 may be a single speed fan.

The electronic expansion valve (EEV) 112 is an electronically controlled motor driven EEV. In alternative embodiments, the HVAC system 100 may comprise a thermostatic expansion valve, a capillary tube assembly, and/or any other suitable metering device other than an EEV. The EEV 112 may comprise and/or be associated with a refrigerant check valve and/or refrigerant bypass for use when a direction of refrigerant flow through the EEV 112 is such that the EEV 112 is not intended to meter or otherwise substantially restrict flow of the refrigerant through the EEV 112.

Outdoor unit 104 comprises an outdoor heat exchanger 114, a compressor 116, an outdoor fan 118, an outdoor metering device 120, and a reversing valve 122. Outdoor heat exchanger 114 is a spine fin heat exchanger configured to allow heat exchange between refrigerant carried within internal passages of the outdoor heat exchanger 114 and fluids that contact the outdoor heat exchanger 114 but that are kept segregated from the refrigerant. In other embodiments, outdoor heat exchanger 114 may comprise a plate fin heat exchanger, a microchannel heat exchanger, or any other suitable type of heat exchanger.

The compressor 116 is a multiple speed scroll type compressor configured to selectively pump refrigerant at a plurality of mass flow rates. In alternative embodiments, the compressor 116 may comprise a modulating compressor capable of operation over one or more speed ranges, the compressor 116 may comprise a reciprocating type compressor, the compressor 116 may be a single speed compressor, and/or the compressor 116 may comprise any other suitable refrigerant compressor and/or refrigerant pump.

The outdoor fan 118 is an axial fan comprising a fan blade assembly and fan motor configured to selectively rotate the fan blade assembly. In other embodiments, the outdoor fan 118 may comprise a mixed-flow fan, a centrifugal blower, and/or any other suitable type of fan and/or blower. The outdoor fan 118 is configured as a modulating and/or variable speed fan capable of being operated at many speeds over one or more ranges of speeds. In other embodiments, the outdoor fan 118 may be configured as a multiple speed fan capable of being operated at a plurality of operating speeds by selectively electrically powering different ones of multiple electromagnetic windings of a motor of the outdoor fan 118. In yet other embodiments, the outdoor fan 118 may be a single speed fan.

The outdoor metering device 120 is a thermostatic expansion valve. In alternative embodiments, the outdoor metering device 120 may comprise an electronically controlled motor driven EEV similar to EEV 112, a capillary tube assembly, and/or any other suitable metering device. The outdoor metering device 120 may comprise and/or be associated with a refrigerant check valve and/or refrigerant bypass for use when a direction of refrigerant flow through the outdoor metering device 120 is such that the outdoor metering device 120 is not intended to meter or otherwise substantially restrict flow of the refrigerant through the outdoor metering device 120.

The reversing valve 122 is a so-called four-way reversing valve. The reversing valve 122 may be selectively controlled to alter a flow path of refrigerant in the HVAC system 100 as described in greater detail below. The reversing valve 122 may comprise an electrical solenoid or other device configured to selectively move a component of the reversing valve 122 between operational positions.

The system controller 106 may comprise a touchscreen interface for displaying information and for receiving user inputs. The system controller 106 may display information related to the operation of the HVAC system 100 and may receive user inputs related to operation of the HVAC system 100. However, the system controller 106 may further be operable to display information and receive user inputs tangentially and/or unrelated to operation of the HVAC system 100. In some embodiments, the system controller 106 may comprise a temperature sensor and may further be configured to control heating and/or cooling of zones associated with the HVAC system 100. In some embodiments, the system controller 106 may be configured as a thermostat for controlling supply of conditioned air to zones associated with the HVAC system.

In some embodiments, the system controller 106 may selectively communicate with an indoor controller 124 of the indoor unit 102, with an outdoor controller 126 of the outdoor unit 104, and/or with other components of the HVAC system 100. In some embodiments, the system controller 106 may be configured for selective bidirectional communication over a communication bus 128. In some embodiments, portions of the communication bus 128 may comprise a three-wire connection suitable for communicating messages between the system controller 106 and one or more of the HVAC system 100 components configured for interfacing with the communication bus 128. Still further, the system controller 106 may be configured to selectively communicate with HVAC system 100 components and/or other device 130 via a communication network 132. In some embodiments, the communication network 132 may comprise a telephone network and the other device 130 may comprise a telephone. In some embodiments, the communication network 132 may comprise the Internet and the other device 130 may comprise a so-called smartphone and/or other Internet enabled mobile telecommunication device.

The indoor controller 124 may be carried by the indoor unit 102 and may be configured to receive information inputs, transmit information outputs, and otherwise communicate with the system controller 106, the outdoor controller 126, and/or any other device 130 via the communication bus 128 and/or any other suitable medium of communication. In some embodiments, the indoor controller 124 may be configured to communicate with an indoor personality module 134, receive information related to a speed of the indoor fan 110, transmit a control output to an electric heat relay, transmit information regarding an indoor fan 110 volumetric flow-rate, communicate with and/or otherwise affect control over an air cleaner 136, and communicate with an indoor EEV controller 138. In some embodiments, the indoor controller 124 may be configured to communicate with an indoor fan controller 142 and/or otherwise affect control over operation of the indoor fan 110. In some embodiments, the indoor personality module 134 may comprise information related to the identification and/or operation of the indoor unit 102 and/or a position of the outdoor metering device 120.

In some embodiments, the indoor EEV controller 138 may be configured to receive information regarding temperatures and/or pressures of the refrigerant in the indoor unit 102. More specifically, the indoor EEV controller 138 may be configured to receive information regarding temperatures and pressures of refrigerant entering, exiting, and/or within the indoor heat exchanger 108. Further, the indoor EEV controller 138 may be configured to communicate with the EEV 112 and/or otherwise affect control over the EEV 112.

The outdoor controller 126 may be carried by the outdoor unit 104 and may be configured to receive information inputs, transmit information outputs, and otherwise communicate with the system controller 106, the indoor controller 124, and/or any other device 130 via the communication bus 128 and/or any other suitable medium of communication. In some embodiments, the outdoor controller 126 may be configured to communicate with an outdoor personality module 140 that may comprise information related to the identification and/or operation of the outdoor unit 104. In some embodiments, the outdoor controller 126 may be configured to receive information related to an ambient temperature associated with the outdoor unit 104, information related to a temperature of the outdoor heat exchanger 114, and/or information related to refrigerant temperatures and/or pressures of refrigerant entering, exiting, and/or within the outdoor heat exchanger 114 and/or the compressor 116. In some embodiments, the outdoor controller 126 may be configured to transmit information related to monitoring, communicating with, and/or otherwise affecting control over the outdoor fan 118, a compressor sump heater, a solenoid of the reversing valve 122, a relay associated with adjusting and/or monitoring a refrigerant charge of the HVAC system 100, a position of the EEV 112, and/or a position of the outdoor metering device 120. The outdoor controller 126 may further be configured to communicate with a compressor drive controller 144 that is configured to electrically power and/or control the compressor 116.

The HVAC system 100 is shown configured for operating in a so-called cooling mode in which heat is absorbed by refrigerant at the indoor heat exchanger 108 and heat is rejected from the refrigerant at the outdoor heat exchanger 114. In some embodiments, the compressor 116 may be operated to compress refrigerant and pump the relatively high temperature and high pressure compressed refrigerant from the compressor 116 to the outdoor heat exchanger 114 through the reversing valve 122 and to the outdoor heat exchanger 114. As the refrigerant is passed through the outdoor heat exchanger 114, the outdoor fan 118 may be operated to move air into contact with the outdoor heat exchanger 114, thereby transferring heat from the refrigerant to the air surrounding the outdoor heat exchanger 114. The refrigerant may primarily comprise liquid phase refrigerant and the refrigerant may flow from the outdoor heat exchanger 114 to the EEV 112 through and/or around the outdoor metering device 120 which does not substantially impede flow of the refrigerant in the cooling mode. The EEV 112 may meter passage of the refrigerant through the EEV 112 so that the refrigerant downstream of the EEV 112 is at a lower pressure than the refrigerant upstream of the EEV 112. The pressure differential across the EEV 112 allows the refrigerant downstream of the EEV 112 to expand and/or at least partially convert to a two-phase (vapor and gas) mixture. The two-phase refrigerant may enter the indoor heat exchanger 108. As the refrigerant is passed through the indoor heat exchanger 108, the indoor fan 110 may be operated to move air into contact with the indoor heat exchanger 108, thereby transferring heat to the refrigerant from the air surrounding the indoor heat exchanger 108, and causing evaporation of the liquid portion of the two-phase mixture. The refrigerant may thereafter re-enter the compressor 116 after passing through the reversing valve 122.

To operate the HVAC system 100 in the so-called heating mode, the reversing valve 122 may be controlled to alter the flow path of the refrigerant, the EEV 112 may be disabled and/or bypassed, and the outdoor metering device 120 may be enabled. In the heating mode, refrigerant may flow from the compressor 116 to the indoor heat exchanger 108 through the reversing valve 122, the refrigerant may be substantially unaffected by the EEV 112, the refrigerant may experience a pressure differential across the outdoor metering device 120, the refrigerant may pass through the outdoor heat exchanger 114, and the refrigerant may reenter the compressor 116 after passing through the reversing valve 122. Most generally, operation of the HVAC system 100 in the heating mode reverses the roles of the indoor heat exchanger 108 and the outdoor heat exchanger 114 as compared to their operation in the cooling mode.

Referring now to FIG. 2, a simplified schematic diagram of the air circulation paths for a structure 200 conditioned by two HVAC systems 100 is shown. In this embodiment, the structure 200 is conceptualized as comprising a lower floor 202 and an upper floor 204. The lower floor 202 comprises zones 206, 208, and 210 while the upper floor 204 comprises zones 212, 214, and 216. The HVAC system 100 associated with the lower floor 202 is configured to circulate and/or condition air of lower zones 206, 208, and 210 while the HVAC system 100 associated with the upper floor 204 is configured to circulate and/or condition air of upper zones 212, 214, and 216.

In addition to the components of HVAC system 100 described above, in this embodiment, each HVAC system 100 further comprises a ventilator 146, a prefilter 148, a humidifier 150, and a bypass duct 152. The ventilator 146 may be operated to selectively exhaust circulating air to the environment and/or introduce environmental air into the circulating air. The prefilter 148 may generally comprise a filter media selected to catch and/or retain relatively large particulate matter prior to air exiting the prefilter 148 and entering the air cleaner 136. The humidifier 150 may be operated to adjust a humidity of the circulating air. The bypass duct 152 may be utilized to regulate air pressures within the ducts that form the circulating air flow paths. In some embodiments, air flow through the bypass duct 152 may be regulated by a bypass damper 154 while air flow delivered to the zones 206, 208, 210, 212, 214, and 216 may be regulated by zone dampers 156.

Still further, each HVAC system 100 may further comprise a zone thermostat 158 and a zone sensor 160. In some embodiments, a zone thermostat 158 may communicate with the system controller 106 and may allow a user to control a temperature, humidity, and/or other environmental setting for the zone in which the zone thermostat 158 is located. Further, the zone thermostat 158 may communicate with the system controller 106 to provide temperature, humidity, and/or other environmental feedback regarding the zone in which the zone thermostat 158 is located. In some embodiments, a zone sensor 160 may communicate with the system controller 106 to provide temperature, humidity, and/or other environmental feedback regarding the zone in which the zone sensor 160 is located.

While HVAC systems 100 are shown as a so-called split system comprising an indoor unit 102 located separately from the outdoor unit 104, alternative embodiments of an HVAC system 100 may comprise a so-called package system in which one or more of the components of the indoor unit 102 and one or more of the components of the outdoor unit 104 are carried together in a common housing or package. The HVAC system 100 is shown as a so-called ducted system where the indoor unit 102 is located remote from the conditioned zones, thereby requiring air ducts to route the circulating air. However, in alternative embodiments, an HVAC system 100 may be configured as a non-ducted system in which the indoor unit 102 and/or multiple indoor units 102 associated with an outdoor unit 104 is located substantially in the space and/or zone to be conditioned by the respective indoor units 102, thereby not requiring air ducts to route the air conditioned by the indoor units 102.

Still referring to FIG. 2, the system controllers 106 may be configured for bidirectional communication with each other and may further be configured so that a user may, using any of the system controllers 106, monitor and/or control any of the HVAC system 100 components regardless of which zones the components may be associated. Further, each system controller 106, each zone thermostat 158, and each zone sensor 160 may comprise a humidity sensor. As such, it will be appreciated that structure 200 is equipped with a plurality of humidity sensors in a plurality of different locations. In some embodiments, a user may effectively select which of the plurality of humidity sensors is used to control operation of one or more of the HVAC systems 100.

Referring now to FIGS. 3-5, cutaway views of an electronic expansion valve (EEV) 112 configured in a metering position, configured in a fully open position, and configured in a fully closed position are shown, respectively, according to embodiments of the disclosure. The EEV 112 generally comprises a valve body 302, a side port 304, and an inline port 306. The EEV 112 further comprises an upper valve portion 310 that extends from the valve body 302 along an axis 320 that is coincident with the inline port 306. Generally, the valve body 302, the side port 304, the inline port 306, and the upper valve portion 310 define a valve cavity 338 through which refrigerant may flow. The EEV 112 also comprises a selectively movable obturator 316 connected to an obturator shaft 318 and that is substantially axially aligned with axis 320. The obturator shaft 318 may generally be connected to a rotor 314 that has a cylindrically-shaped exterior surface. The obturator shaft 318 may generally affix to the rotor 314 by a push nut 324. The rotor 314 comprises a rotor magnet 326 which may be generally affixed to the exterior surface of the rotor 314. The rotor 314 and rotor magnet 326 are encapsulated by a rotor cover 328 that is configured such that an open end of the rotor cover 328 mates to the valve body 302, thereby forming a rotor cavity that provides clearance for a longitudinal movement of the rotor 314 along axis 320.

The EEV 112 also comprises an electronically controlled motor 330. In some embodiments, the motor 330 comprises a stepper motor. The motor 330 radially surrounds the rotor cover 328 and is configured to selectively change a position of the rotor 314. Electrical command pulses applied to the motor 330 may cause angular rotation of the rotor magnet 326. The rotor 314 is configured with rotor threads 322 on the inner surface of the rotor 314 and the rotor threads 322 interlock with valve body threads 312 located on the outer surface of the upper valve portion 310. The interlocking rotor threads 322 and valve body threads 312 are configured to allow the rotor 314 to rotate about the upper valve portion 310, such that the rotor 314 moves longitudinally along the axis 320, thereby driving the obturator 316 similarly along the axis 320. When in a metering position, the obturator 316 is generally configured to restrict refrigerant flow through the valve cavity 338 based on the longitudinal position of the obturator 316. The obturator 316 may be configured in a conical or frustoconical shape to interface with a complimentary valve seat 308, such that when the obturator 316 is positioned within the valve seat 308, refrigerant flow through the valve cavity 338 from the side port 304 to the inline port 306 is restricted. While in some embodiments the obturator 316 may comprise a conical or frustoconical shape, in alternative embodiments an obturator 316 or a complimentary valve seat 308 may comprise any other suitable shape for restricting or preventing flow of refrigerant through the valve cavity 338. When the obturator 316 is driven into the valve seat 308 at a fully closed position as shown in FIG. 5, flow of refrigerant through the valve cavity 338 may be prevented.

The EEV 112 also comprises a first sensor 332 and a second sensor 334. The first sensor 332 and the second sensor 334 are generally longitudinally offset relative to each other along axis 320. The longitudinal offset distance between the first sensor 332 and the second sensor 334 may generally relate to a longitudinal travel distance of the rotor 314 along axis 320 between the fully open position (shown in FIG. 4) to the fully closed position (shown in FIG. 5). In some embodiments, the first sensor 332 and the second sensor 334 may be aligned angularly about axis 320. In other embodiments, the first sensor 332 and the second sensor 334 may be offset angularly relative to each other about axis 320 while still maintaining a longitudinal displacement along axis 320. In other embodiments, the EEV 112 may comprise plurality of sensors disposed longitudinally along axis 320 with various offset distances relative to each other. In yet other embodiments, an EEV 112 may comprise a plurality of sensors disposed longitudinally along axis 320 and offset angularly relative to each other at various intervals about axis 320. In yet other embodiments, an EEV 112 may comprise a plurality of sensors disposed laterally at various distances from the axis 320. Generally, the sensors are enclosed within the rotor cover 328 and located in the rotor cavity 336.

In some embodiments, the first sensor 332 and second sensor 334 may comprise Hall Effect sensors. In alternative embodiments, the first sensor 332 and second sensor 334 may comprise electro-optical sensors. In yet other embodiments, the first sensor 332 and second sensor 334 may comprise electronic proximity (inductive) sensors. Generally, the first sensor 332 and second sensor 334 may be electrically coupled to the indoor EEV controller 138. In other embodiments, the first sensor 332 and the second sensor 334 may be electrically coupled to the indoor controller 124. The first sensor 332 and the second sensor 334 may generally be configured to communicate with the indoor EEV controller 138 and/or the indoor controller 124. In some embodiments, the first sensor 332 and the second sensor 334 may be configured to transmit information about the EEV 112 to the indoor EEV controller 138 and/or the indoor controller 124.

Still referring to FIGS. 3-5, the first sensor 332 and the second sensor 334 may be configured to detect the proximity of the rotor magnet 326. During operation, the rotor 314 may generally be positioned in a metering position as shown in FIG. 3. In a metering position, the obturator 316 partially restricts flow of refrigerant through the valve cavity 338. The longitudinal position of the obturator 316 may be adjusted during operation to allow more or less refrigerant flow through the EEV 112. When more refrigerant flow is required by the HVAC system 100, the EEV 112 may selectively move the obturator 316 to an alternate metering position relatively more open, thereby retracting the obturator along axis 320 and away from the valve seat 308. When less refrigerant flow is required by the HVAC system 100, the EEV 112 may selectively move the obturator 316 to an alternate metering position relatively more closed, thereby moving the obturator along axis 320 and toward the valve seat 308.

As the obturator 316 moves toward a fully open position (shown in FIG. 4), the rotor 314 moves in a longitudinal direction along axis 320 and approaches the first sensor 332. This movement causes the rotor magnet 326 to also move closer to the first sensor 332. The first sensor 332 is configured to detect the proximity of the rotor magnet 326 such that a higher magnetic field is detected by the first sensor 332 as the rotor magnet 326 approaches the first sensor 332. The first sensor 332 is generally configured to detect a highest amplitude of magnetic field when the obturator 316 is at the fully open position as shown in FIG. 4. Contrarily, as the rotor magnet 326 approaches the first sensor 332, the rotor magnet 326 increases its distance from the second sensor 334, such that the second sensor 334 detects a decreasing magnetic field from the rotor magnet 326. The second sensor 334 is generally configured to detect a lowest magnetic field when the obturator 316 is in the fully open position as shown in FIG. 4. The first sensor 332 and the second sensor 334 may generally transmit information about the position of the rotor 314, the rotor magnet 326, and/or the obturator 316 to the EEV controller 138.

As the EEV 112 moves toward a fully closed position (shown in FIG. 5), the rotor 314 moves in a longitudinal direction along axis 320 and moves closer to the second sensor 334. This movement causes the rotor magnet 326 to also move closer to the second sensor 334. The second sensor 334 is also configured to detect the proximity of the rotor magnet 326 such that an increasing magnetic field is detected by the second sensor 334 as the rotor magnet 326 moves closer to the second sensor 334. The second sensor 334 is generally configured to detect the highest amplitude of magnetic field at the fully closed position as shown in FIG. 5. Contrarily, as the rotor magnet 326 moves closer to the second sensor 334, the rotor magnet 326 increases its distance from the first sensor 332, such that the first sensor 332 detects a decreasing magnetic field from the rotor magnet 326. The first sensor 332 is generally configured to detect the lowest amplitude of magnetic field at the fully closed position as shown in FIG. 5. Thus, as the rotor magnet 326 moves closer to the second sensor 334, the first sensor 332 and the second sensor 334 may generally transmit information about the position of the rotor 314, the rotor magnet 326, and/or the obturator 316 to the EEV controller 138.

In some embodiments, the information transmitted by the first sensor 332 and the second sensor 334 may generally be used to determine the relative operating position of the obturator 316 along the axis 320. In general, this may be accomplished by comparing relative values of information sent to the indoor EEV controller 138 by the first sensor 332 and the second sensor 334. For example, when a maximum output voltage of either sensor 332, 334 is determined to be 5 volts when the rotor magnet 326 is adjacent to either the first sensor 332 or the second sensor 334, the first sensor 332 may output a signal of 5 volts when the rotor magnet 326 is adjacent to the first sensor 332 at the fully open position as shown in FIG. 4. Alternatively, when the obturator 316 is in the closed position as shown in FIG. 5, the rotor magnet 326 may be longitudinally aligned to the second sensor 334, thereby causing the second sensor 334 to output a signal of 5 volts. When the obturator 316 is positioned in either a fully open position as shown in FIG. 4 or a fully closed position as shown in FIG. 5, the output of the sensor that is not longitudinally aligned with the rotor magnet 326 may be configured to be 0 volts. Alternatively, a sensor 332, 334 that is not longitudinally aligned with the rotor magnet 326 may output a nominal voltage of about 1 volt, so that when the obturator 316 is in the fully open position as shown in FIG. 4, the output of the first sensor 332 may be 5 volts, while the output of the second sensor 334 may be 1 volt. Alternatively, when the obturator 316 is in the fully closed position as shown in FIG. 5, the output of the second sensor 334 may be 5 volts, while the output of the first sensor 332 may be 1 volt.

As shown in FIG. 3, when the obturator 316 is positioned in a metering state, the first sensor 332 and the second sensor 334 may output voltages that are relative to the location of the obturator 316. For example, continuing with the previous example and assuming a linear relationship between the longitudinal alignment of the rotor magnet 326 with a sensor 332, 334, output values for the first sensor 332 and second sensor 334 may both register 3 volts when the EEV 112 is operating at capacity half open position. Additionally, the same EEV 112 operating at ¾ open position may produce an output voltage of 4 volts for the first sensor 332 and 2 volts for the second sensor 334, still assuming a linear relationship. In some embodiments, the EEV controller 138 and/or indoor controller 124 may comprise a table of values for determining the instantaneous operating position the obturator 316. The table comprises predetermined relationships between the position of the obturator 316 and the corresponding output voltages of the first sensor 332 and the second sensor 334. It should be noted that while only one example is provided to illustrate the functionality of the first sensor 332 and second sensor 334 of the EEV 112, the specific output voltages of sensors 332 and 334 may be based on characteristics of the EEV 112, including, but not limited to, the longitudinal travel distance of the rotor 314 along the axis 320, the longitudinal offset distance of the first sensor 332 relative to the second sensor 334 along the axis 320, a size and/or strength of the rotor magnet 326, and/or the dimensions of the rotor cavity 336 as determined by the configuration of the rotor cover 328.

In addition to determining the operating position of the obturator 316, the information sent by the first sensor 332 and the second sensor 334 may be used to determine a longitudinal and/or angular direction of movement of the obturator 316 as measured along the axis 320. As the obturator 316 travels upward along the axis 320 and approaches the first sensor 332, the first sensor 332 may continuously detect an increasing magnetic field strength attributable to the changing position of the rotor magnet 326. In turn, the first sensor 332 will output increasing voltage values as the rotor 314 moves closer to the first sensor and opens the EEV 112. Similarly, as the rotor 314 travels upward along the axis 320 and consequently away from the second sensor 334, the second sensor 334 may continuously experience a decreasing magnetic field strength exhibited by the rotor magnet 326. Thus, the second sensor 334 may continuously output a decreasing voltage as the rotor 314 travels away from the second sensor 334. These ever-changing voltage outputs from the first sensor 332 and the second sensor 334 may generally be used to determine at least one of a longitudinal and/or angular movement of the obturator 316.

In some embodiments, knowing the position and direction of movement of the rotor 314 in an EEV 112 may be useful in verifying correct function of the motor 330 of an EEV 112. In other embodiments, position information rendered by the first sensor 332 and the second sensor 334 may be used to calibrate the obturator of the EEV 112. Currently, an EEV 112 must reset itself to calibrate, which requires fully opening or fully closing the EEV 112 as shown in FIG. 4 and FIG. 5, respectively. Position feedback of the EEV 112 as determined by the first sensor 332 and the second sensor 334 may thus eliminate the requirement for an EEV 112 to fully open or fully close to calibrate itself, thus allowing calibration of an EEV 112 at any position. Eliminating the current requirement to reset an EEV may also allow calibration of the EEV 112 as well as faster startup times for an HVAC system. In some embodiments, position information may be used to control the position of an obturator 316 rather than relying on the function of a motor 330 of an EEV 112 to control the position. In this instance, feedback from the first sensor 332 and second sensor 334 may be sent to the indoor EEV controller 138. Based on a subcooling model or other parameters of the HVAC system 100, the EEV controller 138 may then adjust the position of the obturator 316 accordingly. Furthermore, in some embodiments, position information supplied by the first sensor 332 and second sensor 334 may also be useful in monitoring steady state operation of the HVAC system 100.

A change in the output voltage of the first sensor 332 and the second sensor 334 may also be used to determine linear speed of the obturator 316 as measured along the axis 320. As stated, the position of the obturator 316 may be associated with particular voltage outputs of the first sensor 332 and second sensor 334. As stated, the direction of movement of the obturator 316 may also be calculated from the output voltages rendered by the first sensor 332 and the second sensor 334. Accordingly, the changes in the output voltages from the first sensor 332 and the second sensor 334 may be determined over a particular time increment to determine the instantaneous speed of the obturator 316 traveling in a linear direction along the axis 320. In some embodiments, determining the speed of the obturator 316 travel along the axis 320 may increase controllability of the EEV 112. In other embodiments, it may be useful in monitoring the function of the motor 330 of the EEV 112. For example, an EEV 112 is generally subject to the accumulation of dirt and/or corrosion when subjected to operating conditions. A slow moving obturator 316 could alter performance of the HVAC system 112 and further cause a delay in the HVAC system 100 realizing the effects of adjustment of the EEV 112. Knowledge of a dirty, corroded EEV 112 could warrant replacement and/or cleaning to restore system peak performance. Thus, in some embodiments, determining the linear speed of an obturator 316 along axis 320 may serve as a troubleshooting function.

In addition to determining the position, direction of movement, and linear speed of the obturator 316, rotational speed (RPM) and angular displacement may also be determined based on the outputs provided by the first sensor 332 and second sensor 334. This is accomplished by utilizing an algorithm to translate linear speed into rotational speed based on a given thread pitch of the valve body threads 312 and the rotor threads 322. Furthermore, if a distance traveled by the obturator 316 is known along the axis 320, the angular displacement may also be determined based on the given thread pitch of the valve body threads 312 and the rotor threads 322. For example, if the thread pitch is 0.050″ and the linear distance traveled by the rotor 314 is determined to be 0.025″, then it can be determined that the rotor 314 made one half rotation, equal to 180 degrees. In some embodiments, the first sensor 332 and the second sensor 334 may be aligned longitudinally. However, in other embodiments, the first sensor 332 and the second sensor 334 may be offset angularly with respect to axis 320 based on the configuration of the EEV 112. In some embodiments, determining the angular speed and/or angular displacement through the first sensor 332 and the second sensor 334 may increase the controllability of the obturator 316. In other embodiments, determining angular speed and/or angular displacement may be useful to verify the correct obturator 316 location control of an EEV 112. In yet other embodiments, angular speed and/or angular displacement may be used to calibrate an EEV 112. Furthermore, in other embodiments, rotational speed and/or angular displacement may also be used to control the obturator 316 rather than relying on the motor 330 alone. As such, EEV 112 may add functionality and accuracy to the operation of the HVAC system 100.

Referring now to FIG. 6, a cutaway view of an EEV 400 is shown according to an embodiment of the disclosure. It should be noted that EEV 400 is substantially similar to EEV 112. EEV 400 comprises a valve body 402, side port 404, inline port 406, valve seat 408, upper valve portion 410, valve body threads 412, rotor 414, obturator 416, obturator shaft 418, axis 420, rotor threads 422, push nut 424, rotor magnet 426, rotor cover 428, motor 430, first sensor 432, second sensor 434, rotor cavity 436, and valve cavity 438. Depending on the configuration of the HVAC system 100, the first sensor 432 and the second sensor 434 may generally be configured to communicate with the indoor EEV controller 138 and/or the indoor controller 124. As with EEV 112, the first sensor 432 and the second sensor 434 are generally disposed longitudinally relative to each other along axis 420. In some embodiments, the first sensor 432 and the second sensor 434 may be aligned longitudinally. However, in other embodiments, the first sensor 432 and the second sensor 434 may be offset angularly about axis 420 based on the configuration of the EEV 112.

EEV 400 generally comprises a plurality of triggers 440. In some embodiments, the triggers 440 may comprise magnets. In other embodiments, the triggers 440 may comprise inductors. In yet other embodiments, the triggers 440 may comprise an optical catalyst capable of optical detection (i.e. contrasting color). The triggers 440 are generally carried by the rotor magnet 426 and displaced longitudinally along the rotor magnet 426 substantially parallel to axis 420. The triggers 440 are generally also configured to surround the rotor 414 and/or rotor magnet 426 radially, such that each trigger 440 at a different longitudinal location as determined along the axis 420 comprises a single element. In other embodiments, however, each trigger 440 at a different longitudinal location as determined along the axis 420 may be divided into a plurality of substantially similar-sized adjacent pieces that radially surround the rotor 414 and/or rotor magnet 426 to form a single trigger 440. The placement of the triggers 440 within the rotor magnet 426 or on the outer surface of the rotor magnet 426 may be determined by the configuration of the EEV 400, including but not limited to, the strength of the rotor magnet 426, the strength of the triggers 440, and the proximity of the rotor magnet 426 to the rotor cover 428. In some embodiments, the triggers 440 may be located along the inner part of the rotor magnet 426, substantially adjacent to the rotor 414 as shown in FIG. 6. In other embodiments, the triggers 440 may be located substantially towards the outer surface of the rotor magnet 426, such that the outermost surface of the triggers 440 is substantially aligned with the outer surface of the rotor magnet 426. In yet other embodiments, the triggers 440 may be located at any location within the rotor magnet 426 between the inner surface of the rotor magnet 426 substantially adjacent to the rotor 414 and the outer surface of the rotor magnet 426. In alternative embodiments, the triggers 440 may be placed on the outer surface of the rotor magnet 426 and extend outward from the outer surface of the rotor magnet 426 towards the rotor cover 428, thus protruding from the rotor magnet 426. In yet other embodiments, the EEV 400 may comprise a plurality of triggers 440 substantially adjacent to each other, such that the trigger 440 configuration forms the rotor magnet 426.

Still referring to FIG. 6, the triggers 440 may generally be configured such that trigger 440′ comprises a highest magnetic strength, triggers 440′ on the top and bottom limits of the configuration comprise a lowest magnetic strength, and triggers 440″ located between trigger 440′ and each of triggers 440′″ comprise an intermediate magnetic strength between that of trigger 440′ and trigger 440′. While only one intermittent strength trigger 440″ is shown in FIG. 6 between highest magnetic strength trigger 440′ and each of the lowest magnetic strength triggers 440′″, in some embodiments, the EEV 400 may comprise a plurality of intermediate magnetic strength triggers 440″ located between the highest strength trigger 440′ and each of the lowest strength triggers 440′″. In embodiments where the EEV 400 comprises a plurality of intermediate strength triggers 440″ between the highest strength trigger 400′ and the lowest strength trigger 440″, the plurality of intermediate strength triggers 440″ may generally be configured in order of decreasing magnetic strength starting with the intermediate strength triggers 440″ located closest to the highest strength trigger 440′ and radiating outward towards either of the lowest strength triggers 440′″ along the axis 320 in a configuration of decreasing magnetic strength.

The first sensor 432 and second sensor 434 are configured to detect the pattern of magnetic fields emitted from the trigger 440 configuration. For illustration purposes, the top of the trigger 440 configuration means the furthest distance along axis 420 relative to the valve seat 408, and the bottom of the trigger 440 configuration means the closest distance along axis 420 relative to the valve seat 408. The first sensor 432 may generally be configured to detect the highest strength trigger 440′ when the obturator 416 is in the fully open position as shown in FIG. 6 such that the first sensor 432 outputs the highest known voltage for the trigger 440 configuration. Additionally, the second sensor 434 may generally be configured to detect the lowest strength trigger 440′″ located at the bottom of the trigger 440 configuration when the obturator 416 is in the fully open position as shown in FIG. 6 and thus output the lowest known voltage for the trigger 440 configuration. At the fully closed position, the second sensor 434 may generally be configured to detect the highest strength trigger 440′, thus outputting the highest known voltage for the trigger 440 configuration, and the first sensor 432 may generally be configured to detect the lowest strength trigger 440′″ located at the top of the trigger 440 configuration, thus outputting the lowest known voltage for the trigger 440 configuration. From the open position as shown in FIG. 6, when the EEV 400 begins to close, the rotor 414 will rotate about the axis 420 driving the obturator 416 towards the valve seat 408. As the EEV 400 moves towards the closed position, the first sensor 432 will begin to detect intermediate strength trigger 440″ located above highest strength trigger 440′ thus outputting a lower voltage than when it was detecting the highest strength trigger 440′. The second sensor 434 will begin to detect trigger 440″ located below highest strength trigger 440′, thus outputting a higher voltage than when the second sensor 434 was detecting the lowest strength sensor 440′″ at the bottom of the trigger 440 configuration. Accordingly, the first sensor 432 will continue to detect a decreasing strength magnetic field and output a decreasing voltage, and the second sensor 434 will continue to detect an increasing strength magnetic field and output an increasing voltage as the obturator 416 closes. Contrarily, the first sensor 432 will detect an increasing strength magnetic field and output an increasing voltage, and the second sensor 434 will detect a decreasing strength magnetic field and output a decreasing voltage as the obturator 416 opens.

In other embodiments, the triggers 440 may comprise a different configuration, where a highest strength trigger 440′ is located at the top and bottom of the trigger 440 configuration, and the lowest magnetic strength trigger 440′″ is located in the center of the configuration. In some embodiments where the lowest strength trigger 440′″ is located in the center of the trigger 440 configuration, and wherein the EEV 400 comprises a plurality of intermediate strength triggers 440″, the intermediate strength triggers 440″ may be arranged between the lowest strength trigger 440′″ and each of the highest strength triggers 440′ in an order of increasing magnetic strength starting with the intermediate strength trigger 440″ most adjacent to lowest strength trigger 440′″ and radiating towards each of the highest strength triggers 440′ located at the top and bottom of the trigger 440 configuration.

In such embodiments, at the obturator 316 open position, the first sensor 432 may be configured to detect the lowest magnetic strength trigger 440′″ located in the center of the trigger 440 configuration, and the second sensor 434 may be configured to detect the highest strength trigger 440′ located at the bottom of the trigger 440 configuration. Accordingly, as the obturator 416 closes, the first sensor 432 may be configured to detect an increasing strength magnetic field, and the second sensor 434 may be configured to detect a decreasing strength magnetic field, until the EEV 400 reaches the fully closed position, wherein the first sensor 432 would detect the highest strength trigger 440′ located at the top of the trigger 440 configuration and the second sensor 434 would detect the lowest strength trigger 440′″ located in the center of the trigger 440 configuration. In yet other embodiments, the triggers 440 may comprise a substantially similar magnetic strength. Such triggers 440 may amplify the magnetic field emitted from the rotor to provide enhanced detection by the first sensor 432 and the second sensor 434. In alternative embodiments, the triggers 440 may comprise a non-linear pattern configured such that the first sensor 432 and the second sensor 434 may detect exaggerated increases and/or decreases in magnetic field strength as the obturator 416 changes position. For example, the configuration from top to bottom could comprise the following trigger 440 configuration: 440″ (Top); 440′; 440′″; 440′ (Center); 440′″; 440′; 440″ (Bottom). Large variances in magnetic field strength detected by the first sensor 432 and the second sensor 434 may provide a wider range of output voltages from the sensors and thus increase the accuracy of measurement of the EEV 400 position and other functional parameters. In yet other embodiments, the EEV 400 may comprise only three triggers 440 having one highest strength trigger 440′ and two of either intermediate triggers 440″ or lowest strength triggers 440′ arranged substantially similarly to any of the previously described embodiments, wherein the first sensor 432 and the second sensor 434 are configured substantially similar to previously described embodiments.

As with EEV 112, the output voltages from the first sensor 432 and the second sensor 434 may be used to determine the position of the obturator 416 of the EEV 400. Known output voltages may be associated with each trigger 440, such that at any given position of the EEV 400, the output voltages from the first sensor 432 and the second sensor 434 may be used to determine the position of the triggers 440 and consequently the obturator 416. Such known voltages may be stored in the EEV controller 138 or the indoor controller 124 and used to determine the position of the obturator 416. Utilizing triggers 440 that comprise different magnetic field strengths may also produce a more significant change in the magnetic field detected by the first sensor 432 and the second sensor 434 as the EEV 400 changes position. Consequently, smaller increments of movement may be able to be detected, thus enabling more accurate detection of the position of the EEV 400.

Furthermore, changes in the magnetic field strength emitted by the triggers 440 may also be used to determine the direction of movement. For example, as in FIG. 6, the first sensor 432 may be configured to detect the highest strength trigger 440′ at the fully open position and the second sensor 434 may be configured to detect the lowest strength trigger 440′″ at the fully open position. Thus, as the first sensor 432 detects a decreasing magnetic field strength and the second sensor 434 detects an increasing magnetic field strength as the EEV 400 closes, the first sensor 432 will output continuously decreasing voltages, and the second sensor 434 will output continuously increasing voltages. Similarly to EEV 112, the respective voltage outputs of each sensor 432, 434 may then be used to determine the exact position of the obturator 416, and the change in the voltage outputs of each sensor may be used to determine the direction of movement of the obturator 416. Because EEV 400 is substantially similar to EEV 112, the respective voltage outputs of the first sensor 432 and second sensor 434 in EEV 400 may be used to determine the exact position of the obturator 416. Additionally, output voltages of the first sensor 432 and the second sensor 434 may also be used to determine direction, linear speed, angular rotational speed, and angular displacement of the obturator 416 in the same manner disclosed in EEV 112. The triggers 440 comprising different magnetic field strengths may, however, provide more accurate sensing of such parameters due to the higher magnitude changes that are detected by the first sensor 432 and the second sensor 434 for smaller increments of movement of the EEV 400. Thus, EEV 400 may also provide the same benefits to enhancing HVAC system 100 operation.

Referring now to FIG. 7, a cutaway view of an EEV 500 is shown according to an embodiment of the disclosure. It should be noted that EEV 500 is substantially similar to EEV 400. EEV 500 comprises a valve body 502, side port 504, inline port 506, valve seat 508, upper valve portion 510, valve body threads 512, rotor 514, obturator 516, obturator shaft 518, axis 520, rotor threads 522, push nut 524, rotor magnet 526, rotor cover 528, motor 530, first sensor 532, second sensor 534, rotor cavity 536, valve cavity 538, and a plurality of triggers 540. Depending on the configuration of the HVAC system 100, the first sensor 532 and the second sensor 534 may generally be configured to communicate with the indoor EEV controller 138 and/or the indoor controller 124. As with EEV 400, the first sensor 532 and the second sensor 534 are generally longitudinally offset relative to each other along axis 520. In some embodiments, the first sensor 532 and the second sensor 534 may be aligned longitudinally. However, in other embodiments, the first sensor 532 and the second sensor 534 may be offset angularly based on the configuration of the EEV 500.

EEV 500 generally comprises a rotor extension 542. The rotor extension 542 may generally extend from the top surface of the rotor 514 along axis 520 and comprise a cylindrical shape axially aligned with axis 520. In some embodiments, the rotor extension 542 may comprise an elongated portion of the rotor 514 that extends upward along the axis 520 and beyond the top of the rotor magnet 526. In other embodiments, the rotor extension 542 may comprise a separate component that is permanently secured to the rotor 514 such that any electronic expansion valve may be configured to accept the rotor extension 542. In some instances, the rotor extension 542 may require an elongated rotor cover 528 in order to fully encapsulate the rotor 514 and the rotor extension 542. EEV 500 may also comprise a rotor extension cavity 544. In some embodiments, the rotor extension cavity 544 may provide clearance for the push nut 524. In other embodiments, the obturator shaft 518 may extend into the rotor extension cavity 544, where the push nut 524 may secure the obturator shaft 518 to the top of the rotor extension 542.

The trigger 540 configuration of EEV 500 may be substantially similar to any of the enumerated embodiments of EEV 400. Additionally, the first sensor 532 and second sensor 534 configuration may also be substantially similar to any of the enumerated embodiments of EEV 400. The difference between EEV 500 and EEV 400 is embodied in that triggers 540 in EEV 500 are carried by the rotor extension 542 as opposed to the triggers 440 in EEV 400 being carried by the rotor magnet 426. However, similarly to EEV 400, the respective voltage outputs of the first sensor 532 and second sensor 534 in EEV 500 may be used to determine the position of the EEV 500. Additionally, as with EEV 400, output voltages of the first sensor 532 and the second sensor 532 may also be used to determine direction, linear speed, angular rotational speed, and angular displacement of obturator 516. Thus, EEV 500 may also provide substantially similar benefits to enhancing HVAC system 100 operation.

Referring now to FIG. 8, a cutaway view of an EEV 600 is shown according to an embodiment of the disclosure. It should be noted that EEV 600 is substantially similar to EEV 500. EEV 600 comprises a valve body 602, side port 604, inline port 606, valve seat 608, upper valve portion 610, valve body threads 612, rotor 614, obturator 616, obturator shaft 618, axis 620, rotor threads 622, push nut 624, rotor magnet 626, rotor cover 628, motor 630, first sensor 632, second sensor 634, rotor cavity 636, valve cavity 638, and a plurality of triggers 640. Depending on the configuration of the HVAC system 100, the first sensor 632 and the second sensor 634 may generally be configured to communicate with the indoor EEV controller 138 and/or the indoor controller 124. As with EEV 500, the first sensor 632 and the second sensor 634 are generally longitudinally offset relative to each other along axis 620. In some embodiments, the first sensor 632 and the second sensor 634 may be aligned longitudinally along axis 620. However, in other embodiments, the first sensor 632 and the second sensor 634 may be offset angularly based on the configuration of the EEV 600.

While EEV 600 may be substantially similar to EEV 500, EEV 600 does not comprise a rotor extension similar to rotor extension 542 that carries triggers 540 as in EEV 500. Instead the triggers 640 of EEV 600 may generally be carried by the rotor 614. The triggers 640 are generally displaced longitudinally from the rotor magnet 626 along the axis 620 such that the triggers 640 are located below the rotor magnet 626. The trigger 640 configuration of EEV 600 may be substantially similar to any of the enumerated embodiments of EEV 500. Thus, in some embodiments, the triggers 640 may be embedded within a portion of the rotor 614. In other embodiments, the triggers 640 may be located on the outer surface of the rotor 614 and extend outward from the outer surface of the rotor 614 towards the rotor cover 628, thus protruding from the rotor 614. Additionally, the first sensor 632 and second sensor 634 configuration may also be substantially similar to any of the enumerated embodiments of EEV 500. Therefore, similarly to EEV 500, the respective voltage outputs of the first sensor 632 and second sensor 634 in EEV 600 may be used to determine the position of the EEV 600. Additionally, as with EEV 500, output voltages of the first sensor 632 and the second sensor 634 may also be used to determine direction, linear speed, angular rotational speed, and angular displacement of obturator 616. Thus, EEV 600 may also provide substantially similar benefits to enhancing HVAC system 100 operation.

Referring now to FIG. 9, a partial cutaway view of an EEV 700 is shown according to an embodiment of the disclosure. It should be noted that EEV 700 is substantially similar to EEV 600. EEV 700 comprises a valve body 702, side port 704, inline port 706, valve seat 708, upper valve portion 710, valve body threads 712, rotor 714, obturator 716, obturator shaft 718, axis 720, rotor threads 722, push nut 724, rotor magnet 726, rotor cover 728, motor 730, first sensor 732, second sensor 734, rotor cavity 736, valve cavity 738, and a plurality of triggers 740. Depending on the configuration of the HVAC system 100, the first sensor 732 and the second sensor 734 may generally be configured to communicate with the indoor EEV controller 138 and/or the indoor controller 124. As with EEV 600, the first sensor 732 and the second sensor 734 are generally longitudinally offset relative to each other along axis 720. In some embodiments, the first sensor 732 and the second sensor 734 may be offset angularly. However, in other embodiments, the first sensor 732 and the second sensor 734 may be aligned vertically depending on the configuration off the EEV 700.

As in EEV 600, the triggers 740 in EEV 700 may also be generally carried by the rotor 714. Thus, in some embodiments, the triggers 740 may be embedded within a portion of the rotor 714. In other embodiments, the triggers 740 may be placed on the outer surface of the rotor 714 and extend outward from the outer surface of the rotor 714 towards the rotor cover 728, thus protruding from the rotor 714. However, EEV 700 generally comprises a trigger 740 configuration wherein the triggers 740 are dispersed angularly around the rotor 714 and configured in a helical pattern that is coincidental with the thread pitch of the rotor 714 such that when the rotor 714 rotates about axis 720, adjacent triggers 740 pass a position substantially adjacent to the first sensor 732 and/or the second sensor 734. The triggers 740 may generally be configured such that trigger 740′ comprises the highest magnetic strength, trigger 740′″ comprises the lowest magnetic strength, and triggers 740″ located between highest strength trigger 740′ and each of the triggers 740″ comprise intermediate magnetic strengths between that of highest strength trigger 740′ and lowest strength trigger 740′″. The plurality of intermediate strength triggers 740″ may generally be configured in order of decreasing magnetic strength in a helical pattern around the rotor 714 and coincidental with the thread pitch of the rotor 714 starting with the intermediate strength trigger 740″ located closest to the highest strength trigger 740′ and continuing in the helical pattern around the rotor 714 up to the lowest strength trigger 740′″.

The first sensor 732 and second sensor 734 are configured to detect the pattern of magnetic fields emitted from the trigger 740 configuration as the rotor 714 rotates about axis 720 and subsequent triggers 740 pass the first sensor 732 and the second sensor 734. The second sensor 734 may generally be configured to detect the highest strength trigger 740′ located at the bottom of the trigger 740 configuration when the obturator 716 is in the fully open position as shown in FIG. 9 and thus output a lowest known voltage for the trigger 740 configuration. Additionally the first sensor 732 may generally be offset at an angular displacement from the second sensor 734 and configured to detect an intermediate strength trigger 740″ when the EEV 700 is in the fully open position as shown in FIG. 9 such that the first sensor 732 outputs a known voltage for that specific trigger 740 configuration. At the fully closed position, the first sensor 732 may generally be configured to detect the lowest strength trigger 740′″ located at the top of the trigger 740 configuration, thus outputting a lowest known voltage for the trigger 740 configuration, and the second sensor 734 may generally be configured to detect a known intermediate strength trigger 740″, thus outputting a specific known voltage associated with that intermediate trigger 740″ in the trigger 740 configuration. From the open position as shown in FIG. 9, when the obturator 716 begins to close, the rotor 714 will rotate about the axis 720 driving the obturator 716 towards the valve seat 708. As the obturator 716 moves towards the closed position, the second sensor 734 will begin to detect subsequent intermediate strength triggers 740″ located above highest strength trigger 740′ and in a helical pattern coincidental with the thread pitch of the rotor 714, thus outputting continuously decreasing voltages. The first sensor 734 will also detect subsequent lower strength intermediate strength triggers 740″, thus also outputting continuously decreasing voltages. Contrarily, both sensors 732, 734 will detect an increasing strength magnetic field and output increasing voltages as the obturator 716 opens.

In some embodiments, the triggers 740 may comprise a different configuration, wherein a highest strength trigger 740′ is located at the top of the trigger 740 configuration, and the lowest magnetic strength trigger 740′″ is located at the bottom of the configuration, wherein the intermediate strength triggers 740″ are arranged in order of increasing magnetic strength starting at the bottom lowest strength trigger 740′″ and angularly dispersed in a helical pattern coincidental with the thread pitch of the rotor 714. In other embodiments, the triggers 740 may comprise a non-linear pattern configured such that the first sensor 732 and the second sensor 734 may detect exaggerated increases and/or decreases in magnetic field strength as the obturator 716 changes position. In yet other embodiments, the triggers 740 may comprise any configuration as enumerated in previously disclosed embodiments, such that the respective output voltages from the first sensor 732 and the second sensor 734 may be used to determine the position of the obturator 716. Known output voltages may generally be associated with each trigger 740, such that at any given position of the EEV 700, the output voltages from the first sensor 732 and the second sensor 734 may be used to determine the position of the obturator 716 and consequently the EEV 700. Additionally, as with EEV 600, output voltages of the first sensor 732 and the second sensor 734 may also be used to determine direction, linear speed, angular rotational speed, and angular displacement of obturator 716. Accordingly, EEV 700 may also provide substantially similar benefits to enhancing HVAC system 100 operation.

At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R_l, and an upper limit, R_u, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R_l+k*(R_u-−_l), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Unless otherwise stated, the term “about” shall mean plus or minus 10 percent of the subsequent value. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.

Electronic Expansion Valve

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CPC

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Abstract

Description

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