Patent Application
20170058885
This application claims priority under 35 USC 119 to Brazilian Patent Application No. BR 102015021009-4 filed Aug. 31, 2015 (Aug. 31, 2015), and the entire disclosure of said Brazilian application is hereby incorporated by reference in its entirety into the present specification.
The present invention relates to a method and to a system for protection and diagnosis of a linear compressor. More specifically, it relates to a method and to a system for protection and diagnosis based on the difference between the suction and compression times of a resonant linear compressor.
The search for systems and methods that provide efficient protection to linear compressor is constant, so that a few known methods and systems make use of sensors for controlling piston displacement, vibration sensors, or still electric devices that measure, for example, voltage and current values applied to the compressor.
It is advisable that the protection methods make use of the smallest amount of additional component possible, so that a method based on physical parameters of the compressor will become advantageous chiefly in financial terms.
The prior art discloses means for controlling linear compressor, for instance, the international publication WO 00/16482 is based on crossing the voltage by zero for the consequent adjustment of the compressor's operation frequency to as close as possible to its resonance frequency.
Further, document U.S. Pat. No. 6,812,597, in spite of measuring the compressor cycle times, treats such times independently, without using a relative signal, as proposed in the present invention. The analysis of the cycle times in an independent manner is more subject to variations between compressors, entailing a not so reliable control.
Additionally, patent U.S. Pat. No. 6,616,414 uses electric signals and parameters of the motor of the linear compressor to control the piston stroke. Such parameters comprise electric current, voltage applied, resistance, inductance, among other.
Although the above-mentioned methods and systems have advantages in a few aspects, none of them is based on the calculation of the difference between the operation semicycles (advance and recoil) of the compressor. Further, they operate as methods for actuating the compressor, not for diagnosis and protection.
By calculating such difference, one reduces the variations that may take place between different compressors, thus making it possible to apply it to resonant linear compressors that use any cooling gas.
The present invention aims the protection of a method and a system applied to a resonant linear compressor, which propose to detect compressor break, the impact of the piston against the valves plate and undesired resonances of the mechanism, among other aspects.
The method and the system proposed take are based on the measurement of the advance and recoil times of the compressor piston. Preferably, such times are determined from the piston position and, more specifically, from the crossing by zero of the counter electromotive force (CEMF/FCEM) of the electric motor of the linear compressor.
Subtracting the recoil (suction) time from the advance (compression) time, one obtains a determining decision parameter to achieve the objectives of the present invention.
From the determination of this decision parameter, one can detect the incorrect operation of the compressor and prevent future failures, thus operating as a decision and diagnosis parameter of the linear compressor.
The present invention has the objective of providing a method and a system for protection and diagnosis of a resonant linear compressor, which monitor the compression and suction cycles of the compressor.
It is an additional objective of the present invention to provide a method and a system for protection and diagnosis of a resonant linear compressor that turn off the compressor definitively, in case abnormal operation thereof is detected.
It is a third objective of the present invention to provide a method and a system for protection and diagnosis of a resonant linear compressor, which takes as a basis the measurement of the advance (compression) time of the compressor and of the recoil (suction) time of the compressor.
A fourth objective of the present invention is to provide a method and a system for protection and diagnosis of a resonant linear compressor, which are based on a decision parameter calculated from the difference between the total suction time and the total compression time of the linear compressor.
It is a fifth objective of the present invention to provide a method and a system for protection and diagnosis of a resonant linear compressor, which prevent damage to internal components of the compressor by calculating the decision parameter.
An additional objective of the present invention is to provide a method and a system for protection and diagnosis of a resonant linear compressor, which use the decision parameter to diagnose possible failures in the operation of the linear compressor.
The present invention describes a method for protection and diagnosis of a linear compressor. The linear compressor comprises at least one electronic control, the protection and diagnosis method is configured so as to comprise the steps of: detecting a suction time of the linear compressor, then detecting a compression time of the linear compressor, and calculating a decision parameter equivalent to the difference between the suction time and the compression time.
Additionally, the present invention describes a compressor, and a protection and diagnosis system that are capable of performing the steps mentioned above.
The present invention will now be described in greater detail with reference to an example of embodiment represented in the drawings. The figures show:
As it is already known, the operation of a linear compressor 2 takes place basically through suction and compression of a cooling gas, thus configuring a suction time (piston recoil) and a compression time (piston advance).
By piston advance one should understand compression of the gas and the consequent discharge thereof. By piston recoil one should understand re-expansion of the gas and suction thereof.
Due to the pressure exerted by the gas during the compression cycle, the respective time to compress it ends up being shorter as compared to the suction time.
By work cycles of the compressor, or compression and suction times, one should understand the advance semicycle of the compressor (compression), comprising the compression and the discharge of the cooling gas.
In the same way, for the recoil semicycle of the compressor (suction), re-expansion and suction of the cooling gas take place.
With reference to
In
In an embodiment, the calculation of the suction time ts of the compressor 2 indicated in
wherein M is equivalent to the piston 15 mass and K refers to the constant of the spring 17 shown in
In a similar way, an embodiment for obtaining the compression time tc of the compressor 2 illustrated in
wherein Kg is equivalent to the force exerted by the gas, opposite the piston displacement, as illustrated in
In a preferred embodiment, considering the constant K of the spring to be 95000 N/m, the piston mass to be M=0.18 kg, one would have suction time ts=4324.4 μs. Admitting the constant Kg as 5000 N/m, one would have the compression time shorter than ts, tc being=4214.9 μs.
The present invention proposes a method and a system for protection and diagnosis of a linear compressor 2 based on the compression time tc and suction time ts to detect possible abnormalities in the operation of the compressor and in its components, thus enabling, if desired, definitive interruption of the compressor operation, in case an abnormality is detected.
For this purpose, the method and the system proposed make use of a decision parameter ΔT, which parameter is preferably determined from the expression 3 below:
ΔT=t
s
−t
c, expression 3
According to the above expression, the parameter ΔT depends only on the suction time ts and compression time tc.
The method 1 in question comprises a first step of detecting a suction time ts of the linear compressor, then said method 1 comprises the step of detecting a compression time tc of the linear compressor.
Continuing the description, the method 1 proposed in the present invention comprises the step of calculating the decision parameter ΔT.
As already mentioned, the decision parameter ΔT is calculated from the difference between the suction time ts and the compression time tc, as indicated by the expression:
ΔT=t
s
−t
c,
As already mentioned, such a parameter ΔT is preferably determined by means of the signal of the CEMF (Counter Electromotive Force (FCEM)) from the electric motor of the linear compressor, more precisely from the crossing of the FCEM by zero.
The obtainment of the decision parameter ΔT by means of the FCEM/CEMF is only a preferred feature of the present invention, so that, alternatively, the suction time ts and the compression test tc can be obtained in other ways.
Only by way of example, the times tc and ts might be obtained by using a stroke sensor for the piston, as well as by any method to estimate the position, velocity or acceleration thereof. Estimating devices via electric parameters of the motor also enable one to achieve said times.
The method 1 proposed further comprises the step of storing said decision parameter ΔT in an internal memory 10 of an electronic control of the linear compressor 2. Said step should be carried out simultaneously in the step of calculating the decision parameter ΔT previously informed.
It is important to point out that the steps mentioned above should be carried out at each work cycle of the linear compressor. Thus, in the course of the operation of the compressor 2, new values of the decision parameter ΔT will be stored in the memory 10 of the electronic control 11. The previously stored values should be kept.
Thus, and further with reference to
In this way, at each work cycle of the linear compressor 2 a new value of the decision parameter ΔT will be stored and a new average decision parameter ΔTm will be established.
The method for protection and diagnosis of a linear compressor 1 as proposed in the present invention takes as a basis the values of ΔT and ΔTm to detect abnormalities in the functioning of the compressor 2, and, as a result, interrupt the functioning thereof.
More specifically with respect to the decision parameter ΔT, if the latter is inserted in a previously defined area of operation of the linear compressor, this fact will indicate that the compressor is in normal operation conditions.
Obtainment of the decision parameter ΔT out of the limits of the operation area will indicate possible abnormality in the compressor operation.
For example, considering that the operation area is delimited by a normality range and by a maximum operation limit B, the obtainment of a decision parameter ΔT lower than the normality range may indicate the occurrence of anomalies in the pumping of the cooling gas.
In a similar way, the obtainment of a decision parameter ΔT higher than the maximum operation limit B may represent piston collision against the valve plate of the linear compressor 2.
The normality range is referred to as the lower limit of the operation area and represents values for the decision parameter equal to zero. Thus, the obtainment of any lower ΔT value is an indication of abnormality in the functioning of the linear compressor 2.
On the other hand, the maximum operation limit is referred by the curve B in the graph shown in
In harmony with the foregoing, the regular operation area of the linear compressor is indicated in the graph in question by the hachured region arranged between the maximum limit of operation B and the normality range (ΔT=0). Thus, any value obtained for the decision parameter ΔT that is within the hachured area indicates the operation of the compressor in its normal and acceptable behavior, as referenced by the full line shown in
In a graph of the decision parameter ΔT as a function of the power applied to the compressor, the maximum operation limit B may be obtained from the operation of the compressor 2 in all its conditions of use, thus establishing the maximum acceptable relationship for the compression and suction times and the maximum operation limits for the compressor.
For example, if the compressor 2 is used in a cooling equipment, the curve B is obtained from the operation of the compressor 2 in preferred conditions of maximum condensation, maximum and minimum evaporation, among others.
More specifically, the curve referring to the maximum operation limit B is obtained from the technical characteristics that embrace the compressor operating “envelope”.
Thus, the decision parameter may be used as a means of diagnosis of the operation of a linear compressor and the prediction of failures. In a preferred embodiment, one can detect the collision of the piston of the linear compressor 2 against the valve plate, which would entail an increase in the value of the decision parameter ΔT.
With such addition, ΔT would exceed the region delimited by the maximum limit of operation B, as indicated in
Similarly, one indication of abnormalities in the operation of the linear compressor 2 will occur when the average decision parameter ΔTm is higher than a maximum limit of normality.
If the average decision parameter ΔTm is higher than the maximum limit of normality by a determined number of work cycles n of the compressor 2, the protection and diagnosis method is preferably configured so as to turn off the resonant linear compressor 2 definitively.
If the average decision parameter ΔTm is lower than the maximum limit of normality, the proposed method 1 is configured so as to go on with the electric feed of the linear compressor 2, since in this scenario there are no indications of abnormalities in the functioning of the compressor 2.
Additionally, as already mentioned, from the calculation of the decision parameter ΔT by means of the difference between the suction time ts and compression time tc, one can compare the parameter ΔT with a normality range configured previously in the internal memory 10 of the electronic control 11.
Thus, one should compare the ΔT value with the normality range and, if ΔT is lower than said normality range or higher than the maximum operation limit B, by a determined number of work cycles n of the compressor 2, the power feed of the compressor 2 may be interrupted.
Further, from the determination of the decision parameter ΔT and of its average value ΔTm, one observes in
For example, from the variability indicator K one can preferably interrupt the operation of the compressor when it is detected that the latter is operating at undesired resonance frequencies, which may entail excessive vibrations and, as a result, damage the product.
For this purpose, the variability indicator K should be preferably calculated at each work cycle of the linear compressor 2, from the expression 4 below:
K=ΔT
m−Δt, expression 4
If the absolute value (module value) of the variability indicator K is higher than a resonance pattern, this fact will indicate compressor operation at undesired resonance frequencies.
Thus, if this takes place, the method 1 proposed herein is preferably configured so as to interrupt the power feed of the compressor 2. If no K value exceeds the resonance pattern A, the compressor 2 will continue operating normally.
Thus, from the decision parameter ΔT and of its comparison with the average decision parameter ΔTm (variability indicator K), one can diagnose and prevent operation of the compressor 2 at undesired frequencies. For example, if the variability indicator K is higher than the displacement pattern, the power feed of the compressor 2 may be interrupted. As mentioned before, the curve represented for the variability indicator K is only a preferred representation for such a parameter.
One should mention that the formula set forth for obtaining the variability indicator K is only a preferred one, so that any other formula for dispersion calculation might be used, as for example, standard deviation.
Additionally, the variability indicator K is useful in diagnosing failures that lead the compressor to an unpredictable behavior, for instance, a different behavior for each operation cycle. On the other hand, the decision parameter ΔT is useful in diagnosing failures that lead the compressor to an unwanted, but regular behavior at each work cycle (such as the piston collision against the valve plate).
Further, a typical representation of the behavior of the decision parameter ΔT in a condition of failure of the linear compressor 2 is given in
As can be seen, the behavior of the decision parameter ΔT reveals a high variability and still negative values, as for instance ΔT1.
If one opts for the sequence of the power feed of the linear compressor 2 from the parameters ΔT, ΔTm and K, the proposed method 1 is configured so as to carry out again the step of detecting a suction time ts of the linear compressor 2, thus restarting the previously mentioned steps.
Further with regard to the decision parameter ΔT, the later depends on the compressor operation conditions, such as room temperature, temperature of the cooler and freezer, operation power, and also on mechanical parameters like piston mass, kit mass, piston diameter and spring rigidity. In this way, each compressor 2 will have a behavior for the specific decision parameter ΔT, even if the power applied on each compressor 2 is the same.
The variations in power will affect the ΔT value directly, and the higher the power the higher the value of the decision parameter decision ΔT.
Variations in piston mass (wear) will also affect the ΔT. One may establish that a 10% variation in the piston mass will cause ΔT to vary by 0.4%. Similarly, 10% variation in the kit mass will affect ΔT by 0.6%.
Variations in the spring rigidity are the factor that affects ΔT the most, such variation being also related to the variation in the power applied to the compressor. Tests carried out showed that 10% variation in the spring rigidity will affect ΔT by 13%.
Further, it is valid to mention that carrying out the method proposed herein should not be limited initially to carrying out the step of detecting the suction time ts and then the compression time tc of the linear compressor. One may first detect the compression time tc and then detect the suction time ts.
In a similar way, the decision parameter ΔT may be calculated by subtraction between the compression time tc and the suction time ts, in this case the value obtained would be negative and the due adaptations should be made in the proposed method, and the consequent verification of the acceptance of the ΔT value obtained (as well as of the indicator K and of ΔTm).
The present invention further relates to a system 13 for protection of a linear compressor 2, capable of carrying out the steps of the method described above,
For this purpose, said compressor 2 should comprise at least one internal memory 10 for storing the decision parameter ΔT at each work cycle of the linear compressor. As already mentioned, the decision parameter ΔT is calculated from the difference between the suction time ts and the compression time tc of the compressor 2.
Further, the proposed system 13 is preferably configured so as to interrupt the electric association between a feed source V and the linear compressor 2, if the decision parameter ΔT is lower than a maximum operation limit B by a determined number of work cycles “n” of the linear compressor 2.
Further, said protection system 13 is capable of determining an average decision parameter ΔTm at each work cycle of the linear compressor and preferably interrupt the electric association between the compressor 2 and the feed source V, if said average decision parameter ΔTm is higher than a maximum limit of normality by a determined number of work cycles “n” of the compressor 2.
Additionally, the system 13 is configured so as to detect a variability indicator K through the expression 4 shown before. As already mentioned, through the variability indicator K one can determine operation of the compressor 2 at undesired resonance frequencies and, as a result, interrupt the power feed, if desired.
Finally, the present invention further relates to a linear compressor 2 of a piece of cooling equipment, said linear compressor 2 being electrically associable to a feed source V and comprising at least one internal memory 10 and an electronic control
The proposed linear compressor 2 is configured so as to determine the decision parameter ΔT from the difference between a suction time ts and a compression time tc of the compressor 2. Further, the electronic control 11 is configured so as to preferably interrupt the electric association between the compressor 2 and the feed source V, if the decision parameter ΔT is lower than the normality range or higher than a maximum operation limit B.
Further, the linear compressor 2 is configured so as to determine the average decision parameter ΔTm, so that, if ΔTm is higher than the maximum limit of normality, the electronic control 11 will interrupt the electric feed of the compressor 2.
In harmony with the method 1 and the system 13 described, the compressor 2 is configured so as to determine a variability indicator K and, comparing the indicator K with a resonance pattern, one can detect operation of the compressor 2 at undesired resonance frequencies.
With regard to the maximum limit of normality and to the maximum operation limit B, they are previously stored in the internal memory 10 of the linear compressor 2 from the average values of ΔTm considered to be accepted.
In a similar way, the normality range is previously established in the internal memory 11 from ΔT values considered acceptable. In the graphs shown in
Similarly, acceptable values for the variability indicator K are previously established in the internal memory 11 of the linear compressor 2, since the latter depends on ΔT and ΔTm.
The proposed method and system for protection and diagnosis, from the calculation of the decision parameter ΔT, enable previous detection of damage to components of the linear compressor 2, as well as enable easy viewing of abnormal operation of the compressor.
Further, from the calculation of the decision parameter ΔT, one can protect the compressor against very intense impacts against the valve plate, as well as identify the limit of the compressor piston stroke. In this way, one may use the decision parameter ΔT in techniques of controlling the piston stroke of the linear compressor 2, as well as a means (parameter) for monitoring its operation.
Additionally, said method and system can be applied on resonant linear compressors that make use of any cooling gas, since they are based only on the monitoring of compression and suction cycles of the compressor.
Further, one should not necessarily interrupt the power feed of the compressor, if the value obtained for the decision parameter ΔT, average decision parameter ΔTm and variability indicator K are out of the acceptable limits.
In an alternative embodiment, the achievement of a decision parameter ΔT higher than the maximum operation limit be may be used as information (diagnosis) for automatically deducing the application power of the compressor, thus reducing the ΔT value achieved and causing the compressor to operate normally.
A preferred example of embodiment having been described, one should understand that the scope of the present invention embraces other possible variations, being limited only by the contents of the accompanying claims, which include the possible equivalent.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102015021009-4 | Aug 2015 | BR | national |
