Patent Application
20230025402
The present disclosure relates, in general, to a refrigeration device and, more specifically relates, to a defrost control method of an evaporator of the refrigeration device.
Refrigeration devices, such as air conditioners, are conventionally utilized to adjust temperature within dwellings structures, such as house and offices. In a split-type air conditioner, an indoor unit is located indoors, and an outdoor unit is located outdoors. A frequently encountered challenge with such air conditioners lies with defrosting the outdoor unit, particularly during winter condition where the outdoor unit functions as an evaporator. For example, when the evaporator is active, frost may accumulate on the evaporator and thereby reduce efficiency of the evaporator. In cases where zeotropic refrigerant blends are used as operating fluid in the split-type air conditioner, temperature at an inlet of the evaporator is lower than temperature at an outlet of the evaporator. Hence, amount of frost accumulation at the inlet may be greater than at the outlet of the evaporator.
When the frost formation on the evaporator is not addressed at its beginning, the frost may accumulate on the evaporator over time, and may eventually block air flow across the evaporator, thereby reducing heat transfer efficiency of the evaporator. Known solutions to mitigate the frost formation include electric heating devices disposed within the outdoor unit. However, only a small proportion of heat generated from such electric heating devices is used to melt the frost, while major proportion of the generated heat is lost to air and other components in the outdoor unit. Instances of uncontrolled heating may damage the electric heating devices and may result in repeated defrost cycles unnecessarily.
According to one aspect of the present disclosure, a refrigeration device is disclosed. The refrigeration device includes a circuit comprising an evaporator, a compressor, a condenser, and an expansion valve orderly connected by a refrigerant flow path. The refrigeration device further includes a first sensor configured to sense ambient temperature, a second sensor configured to sense evaporator inlet temperature, at least one microwave module disposed proximal to the evaporator and configured to generate microwaves, and a controller coupled to each of the first sensor, the second sensor, and the microwave module. In an embodiment, the microwave module is disposed proximal to the inlet of the evaporator and around a fan motor of the evaporator. In some embodiments, the microwave module includes a magnetron, a transformer, a diode, and a capacitor. Further, the controller is configured to determine whether a difference in temperature value between the ambient temperature and the evaporator inlet temperature is equal to or greater than a first predetermined temperature value and initiate operation of the microwave module to heat an inlet of the evaporator when the difference in temperature value between the ambient temperature and the evaporator inlet temperature is equal to or greater than the first predetermined temperature value.
In an embodiment, the controller is configured to cease the operation of the microwave module when the difference in temperature value between the ambient temperature and the evaporator inlet temperature is less than the first predetermined temperature value.
In some embodiments, the first sensor is disposed on a periphery of the evaporator. In some embodiments, the controller is configured to initiate the operation of the microwave module when the ambient temperature is less than a predefined ambient temperature value. In an embodiment, the predefined ambient temperature value is about 32° F. In some embodiments, the controller is configured to determine whether a predefined time period has elapsed prior to actuation of the at least one microwave module for a subsequent defrost of the inlet of the evaporator. In a preferred embodiment, the controller is configured to initiate the operation of the microwave module when: (a) the difference in temperature value between the ambient temperature and the evaporator inlet temperature is equal to or greater than the first predetermined temperature value, (b) the ambient temperature is less than the predefined ambient temperature value, such as 32° F., and (c) the predefined time period has elapsed with respect to the previous defrost cycle for the inlet of the evaporator.
In some embodiments, the refrigeration device further includes a third sensor configured to sense evaporator outlet temperature, and a four-way valve disposed between the evaporator and the compressor. The controller is coupled to the third sensor and the four-way valve. The controller is configured to determine whether a difference in temperature value between the ambient temperature and the evaporator outlet temperature is greater than a second predetermined temperature value, and control operation of the four-way valve to initiate a defrost cycle to heat the outlet of the evaporator when the difference in temperature value between the ambient temperature and the evaporator outlet temperature is greater than the second predefined temperature value. In some embodiments, the controller is configured to control operation of the four-way valve to cease the defrost cycle when the difference in temperature value between the ambient temperature and the evaporator outlet temperature is less than the second predetermined temperature value.
In some embodiments, the refrigeration device further includes a first frost sensor disposed proximal to the inlet of the evaporator. The controller is coupled to the first frost sensor and configured to initiate operation of the microwave module based on an input from the first frost sensor to defrost the inlet of the evaporator. In some embodiments, the refrigeration device further includes a second frost sensor disposed proximal to the outlet of the evaporator. The controller is coupled to the second frost sensor and configured to control operation of the four-way valve to initiate the defrost cycle to defrost the outlet of the evaporator, based on an input from the second frost sensor. In some embodiments, the controller is configured to determine whether a predefined time period has elapsed prior to initiation of the defrost cycle by the four-way valve for the subsequent defrost of the outlet of the evaporator. In a preferred embodiment, the controller is configured to initiate the defrost cycle when (a) the difference in temperature value between the ambient temperature and the evaporator outlet temperature is greater than the second predetermined temperature value, (b) the ambient temperature is less than the predefined ambient temperature value, such as 32° F., and (c) the predefined time period has elapsed with respect to the previous defrost cycle for the outlet of the evaporator.
According to another aspect of the present disclosure, a method of operating a refrigeration device is disclosed. The method includes receiving, by a controller, a first input from a first sensor and a second input from a second sensor. The first input is indicative of ambient temperature, and the second input is indicative of evaporator inlet temperature. The method further includes determining, by the controller, whether a difference in temperature value between the ambient temperature and the evaporator inlet temperature is greater than a first predetermined temperature value. The method further includes initiating, by the controller, operation of at least one microwave module to heat an inlet of the evaporator when the difference in temperature value between the ambient temperature and the evaporator inlet temperature is greater than the first predetermined temperature value.
In some embodiments, the method includes initiating, by the controller, operation of the at least one microwave module when the ambient temperature is less than a predefined ambient temperature value.
In some embodiments, the method includes receiving, by the controller, an input from a first frost sensor disposed proximal to the inlet of the evaporator, and initiating, by the controller, the operation the at least one microwave module based on the input from the first frost sensor to defrost the inlet of the evaporator. In some embodiments, the method includes determining, by the controller, whether a predefined time period has elapsed prior to actuation of the at least one microwave module for a subsequent defrost of the inlet of the evaporator.
In some embodiments, the method further includes receiving, by the controller, a third input from a third sensor indicative of evaporator outlet temperature, and determining, by the controller, whether a difference in temperature value between the ambient temperature and the evaporator outlet temperature is greater than a second predetermined temperature value. When the controller determines the difference in temperature value between the ambient temperature and the evaporator outlet temperature being greater than the second predetermined temperature value, the method includes controlling, by the controller, operation of the four-way valve to initiate a defrost cycle to heat the outlet of the evaporator. In some embodiments, the method includes receiving, by the controller, an input from a second frost sensor disposed proximal to the outlet of the evaporator and controlling the operation of the four-way valve to initiate the defrost cycle to defrost the outlet of the evaporator, based on the input from the second frost sensor.
These and other aspects and features of non-limiting embodiments of the present disclosure will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the disclosure in conjunction with the accompanying drawings.
A better understanding of embodiments of the present disclosure (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the embodiments along with the following drawings, in which:
Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding, or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein, are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.
As used herein, the terms “a”, “an” and the like generally carry a meaning of “one or more,” unless stated otherwise. Further, the terms “approximately”, “approximate”, “about”, and similar terms generally refer to ranges that include the identified value within a margin of 20%, 10%, or preferably 5%, and any values therebetween.
Aspects of the present disclosure are directed to a refrigeration device implementing a controlled defrost cycle of an evaporator thereof, which includes localized heating of portions of evaporator affected with frost, thereby minimizing energy consumed by the defrost cycle. Additionally, the present disclosure mitigates effects of non-uniform frost accumulation caused by zeotropic refrigerant glide. Referring to
The circuit 102 includes an evaporator 104, a compressor 106, a four-way valve 108, a condenser 110, and a first expansion valve 112, and a second expansion valve 114 orderly connected by a refrigerant flow path 116. In an embodiment, the circuit 102 includes a zeotropic refrigerant blend, such as a mixture of two or more refrigerants selected from a group including, but not limited to, R-454A, R-454B, R-454C, R-407C, R-407F, and R-407H, flowing along the refrigerant flow path 116. As such, at same pressure level, each component in the zeotropic refrigerant blend has a different dew point temperatures. In cases where ambient temperature is low, for example during winter season, the refrigeration device 100 is configured to operate in a space heating mode. As used herein, the term ‘space heating’ refers to heating the indoor space of the building, where the outdoor unit functions as the evaporator 104 and the indoor unit functions as the condenser 110. The refrigerant flowing through the evaporator 104 is associated with a temperature less than ambient air and hence absorbs heat from the ambient air. Such absorption of the heat allows conversion of liquid refrigerant to vapor refrigerant. The vapor refrigerant flows into the compressor 106, via the four-way valve 108. At the compressor 106, the vapor refrigerant is compressed under high pressure, resulting in increase of temperature thereof. Heated vapor refrigerant flows through the condenser 110, where the vapor refrigerant loses heat to air in the indoor space, thereby heating the indoor space and partially condensing to liquid form. Further, partially condensed warm liquid refrigerant bypasses the first expansion valve 112 and further flows through the second expansion valve 114, where the pressure and temperature associated with the refrigerant is reduced for subsequent space heating cycle. With further fall in temperature of the ambient air, moisture present in the ambient air condenses on the evaporator 104, resulting in formation of frost. Since the refrigerant mixture has a lower saturation temperature at an inlet of the evaporator 104 than at an outlet thereof for same pressure level, frost formation may be higher at the inlet when compared to the outlet of the evaporator 104.
It will be understood that the refrigeration device 100 may be configured to operate in a cooling mode. As used herein, the term ‘cooling mode’ refers to cooling the indoor space, where the outdoor unit functions as the condenser 110 and the indoor unit functions as the evaporator 104. In such cooling mode, operation cycle illustrated in
In some embodiments, the controller 310 may be implemented as a processor, such as one or more microprocessors, microcomputers, digital signal processors, central processing units, state machines, logic circuitries, or any devices that manipulate signals based on operational instructions. Among other capabilities the processor may be configured to fetch and execute computer-readable instructions stored in a memory 312 thereof. Various functions of the processor may be provided using dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by the processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors. Moreover, explicit use of the term “processor” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, but not limited to, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non-volatile storage. Other hardware known to a person skilled in the art may also be included. In some embodiments, the controller 310 may be located in the indoor space and may include a user interface (not shown).
In an embodiment, the microwave module 206 includes a magnetron 314, a power unit 316, and an antenna 318. The power unit 316, amongst other components, includes a transformer 320, a diode 322, and a capacitor 324. The transformer 320, such as a linear transformer, functions as an electronic power converter to supply energy and drive the magnetron 314. The capacitor 324, such as a high voltage capacitor, is connected to the magnetron 314 and the transformer via the diode 322. The magnetron 314 is configured to convert high voltage electrical energy to microwave radiation.
Further, the first sensor 302 is configured to sense ambient temperature ‘TAmb’ and the controller 310 is configured to receive a first input from the first sensor 302 indicative of the ambient temperature ‘TAmb’. The space heating of the indoor space is required when temperature of the indoor space is low, for example during winter season. Additionally, possibility of frost development at the inlet 208 of the evaporator 104 may be high during the winter condition, for example when the ambient temperature ‘TAmb’ is low. Accordingly, in an embodiment, based on the first input, the controller 310 is configured to determine whether the ambient temperature ‘TAmb’ is less than a predefined ambient temperature value ‘TP-Amb’ and actuate the microwave module 206 when the ambient temperature ‘TAmb’ is less than the predefined ambient temperature value ‘TP-Amb’. In an embodiment, the predefined ambient temperature value ‘TP-Amb’ may be about 32° F., which is the freezing point of water, and may be stored in the memory 312 of the controller 310. Since the controller 310 is coupled to the first sensor 302 to receive the first input, the controller 310 may be configured to constantly determine whether the ambient temperature ‘TAmb’ is less than the predefined ambient temperature value ‘TP-Amb’. The ambient temperature ‘TAmb’ being less than the predefined ambient temperature value ‘TP-Amb’ such as 32° F., may be considered as an initial condition to be met for initiating a defrost cycle.
In some embodiments, the first sensor 302 may be located within the indoor space and may be configured to sense temperature of the indoor space. In such an arrangement, the controller 310 may be configured to initiate operation of the microwave module 206 when the temperature of the indoor space is less than a desired temperature. In an example, the desired temperature may be set by the user via the user interface.
Further, the controller 310 is configured to receive a second input from the second sensor 304 indicative of evaporator inlet temperature ‘TInlet’. Based on the second input, the controller 310 is configured to determine whether a difference in temperature value between the ambient temperature ‘TAmb’ and the evaporator inlet temperature ‘TInlet’ is equal to or greater than a first predetermined temperature value ‘T1’. When the difference in temperature value (TAmb−TInlet) is greater than the first predetermined temperature value ‘T1’, the controller 310 is configured to initiate operation of the microwave module 206 to heat the inlet 208 of the evaporator 104. As such, the defrost cycle begins when a second condition is met for initiating the defrost cycle, that is when the difference in temperature value (TAmb−TInlet) is greater than the first predetermined temperature value ‘T1’.
For example, the first predetermined temperature value ‘T1’ may be about 30° F. and may be preset in the memory 312 of the controller 310. When the first condition is met and the second condition is not met, the controller 310 may not initiate the defrost cycle to heat the inlet 208 of the evaporator 104. In cases where the ambient temperature ‘TAmb’ is below 32° F. and a relative humidity of ambient air is low, little or no moisture may accumulate on the inlet 208 of the evaporator 104. As such, the difference in temperature value (TAmb−TInlet) may not reach the first predetermined temperature value ‘T1’. For example, when the ambient temperature ‘TAmb’ is 28° F. and the evaporator inlet temperature ‘TInlet’ is about 15° F., the difference in temperature value (TAmb−TInlet) is about 13° F., which is less than the first predetermined temperature value ‘T1’ of about 30° F. As frost accumulates on the inlet 208 of the evaporator 104, the evaporator inlet temperature ‘TInlet’ falls while the ambient temperature ‘TAmb’ may remain constant. When the evaporator inlet temperature ‘Tinto.’ is about −2° F., the difference in temperature value (TAmb−TInlet) reaches 30° F., which is equal to the first predetermined temperature value ‘T1’ and indicative of a condition of frost formation at the inlet 208 of the evaporator 104. In such a condition, the controller 310 initiates the operation of the microwave module 206, where the antenna 318 amplifies and emanates electron energy at a predefined frequency towards the inlet 208 of the evaporator 104, thereby generating heat. With such arrangement, localized heating at the inlet 208 of the evaporator 104 may be achieved.
With such supply of heat, frost at the inlet 208 of the evaporator 108 may be reduced, thereby reducing the evaporator inlet temperature ‘TInlet’. When the difference in temperature value (TAmb−TInlet) falls below the first predetermined temperature value ‘T1’, the controller 310 is configured to cease the operation of the microwave module 206. In cases where multiple microwave modules 206 are deployed in the outdoor unit 200, the controller 310 may be configured to simultaneously actuate all the microwave modules 206. As such, uniform heating of the inlet 208 of the evaporator 104 may be achieved and localized defrost of the inlet 208 of the evaporator 104 may be ensured. As such, radiation of heat to neighboring components of the outdoor unit 200 may be eliminated, besides reducing power consumption to operate the microwave module 206. In some embodiments, the microwave modules 206 may be oriented in a manner to heat the evaporator tubes at a topmost portion of the outdoor unit 200 which may experience minimum flow of ambient air based on configuration of the fan blades 204. In some embodiments, the controller 310 may be configured to determine whether the second condition is met for initiating the defrost cycle, that is when the difference in temperature value (TAmb−TInlet) is greater than the first predetermined temperature value ‘T1’, without necessarily checking whether the first condition is met.
In some embodiments, as a third condition, the controller 310 may be configured to determine whether a predefined time period has elapsed prior to actuation of the microwave module 206 for a subsequent defrost of the evaporator 104. Such predefined time period may eliminate possibility of any false actuation of the microwave module 206 which may lead to unnecessary heating of the evaporator 104 and power utilization. In a preferred embodiment, the controller 310 is configured to initiate the operation of the microwave module 206 only when: (a) the difference in temperature value between the ambient temperature ‘TAmb’ and the evaporator inlet temperature ‘TInlet’ is equal to or greater than the first predetermined temperature value ‘T1’, (b) the ambient temperature ‘TAmb’ is less than the predefined ambient temperature value ‘TP-Amb’, such as 32° F., and (c) a predefined time period has elapsed with respect to a previous defrost cycle for the inlet 208 of the evaporator 104. In other words, the controller 310 is configured to initiate the operation of the microwave module 206 only when the first, the second, and the third condition is met.
Further, the third sensor 306 is configured to sense evaporator outlet temperature ‘TOutlet’. The controller 310 is configured to receive a third input from the third sensor 308 indicative of the evaporator outlet temperature ‘TOutlet’. Based on the third input, the controller 310 may be configured to determine a difference in temperature value between the ambient temperature ‘TAmb’ and the evaporator outlet temperature ‘TOutlet’ and determine whether the difference in temperature value (TAmb−TOutlet) is greater than a second predetermined temperature value ‘T2’. The controller 310 may be further configured to control operation of the four-way valve 108 (See
With the aid of the four-way valve 108, pressurized refrigerant associated with high temperature is directed to the outdoor unit 200 where the refrigerant loses heat to the evaporator 104, thereby melting the frost at the outlet 308 of the evaporator 104. During such operation, the controller 310 may be configured to cease operation of the fan motor 202 to minimize flow of cold ambient air across the evaporator 104 and reduce additional heat loss from the refrigerant flowing across the evaporator 104. The refrigerant is directed to the indoor unit to lose remaining heat to the indoor space. In an embodiment, the controller 310 is configured to control operation of the four-way valve 108 to cease the defrost cycle when the difference in temperature value (TAmb−TOutlet) is less than the second predetermined temperature value ‘T2’.
In some embodiments, the controller 310 may be configured to determine whether a predefined time period has elapsed prior to actuation of the four-way valve 108 for a subsequent defrost of the outlet 308 of the evaporator 104. Such predefined time period may eliminate possibility of any false actuation of the four-way valve 108 which may lead to unnecessary heating of the evaporator 104 and power utilization. In a preferred embodiment, the controller 310 is configured to control the operation of the four-way valve 108 to initiate the defrost cycle to heat the outlet 308 of the evaporator 104 only when: (a) the difference in temperature value (TAmb−TOutlet) is greater than the second predetermined temperature value ‘T2’, (b) the ambient temperature ‘TAmb’ is less than the predefined ambient temperature value ‘TP-Amb’ such as 32° F., and (c) the predefined time period has elapsed with respect to the previous defrost cycle for the outlet 308 of the evaporator 104.
In some embodiments, frost thickness may be determined using, but limited to, laser displacement gauge measurement, side view photo analysis, digital image processing, optical signal, and neutron radiography conversion measurement.
At step 504, the method 500 includes receiving, by the controller 310, a second input from the second sensor 304, where the second input is indicative of evaporator inlet temperature ‘TInlet’.
At step 506, the method 500 includes determining, by the controller 310, whether a difference in temperature value between the ambient temperature ‘TAmb’ and evaporator inlet temperature ‘TInlet’ is greater than the first predetermined temperature value ‘T1’.
At step 508, the method 500 includes initiating, by the controller 310, operation of the at least one microwave module 206 to heat inlet 208 of the evaporator 104 when the difference in temperature value between the ambient temperature ‘TAmb’ and the evaporator inlet temperature ‘TInlet’ is greater than the first predetermined temperature value ‘T1’.
Although not specifically illustrated in
At step 554, the method 550 includes determining, by the controller 310, whether a difference in temperature value between the ambient temperature ‘TAmb’ and the evaporator outlet temperature ‘TOutlet’ is greater than the second predetermined temperature value ‘T2’.
At step 556, the method 550 includes controlling, by the controller 310, operation of the at least one microwave module 206 to initiate the defrost cycle to heat the outlet 308 of the evaporator 104 when the difference in temperature value between the ambient temperature ‘TAmb’ and the evaporator outlet temperature ‘TOutlet’ is greater than the second predefined temperature value ‘T2’.
Although not specifically illustrated in
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
