This invention is related to the field of refrigeration systems, more specifically to domestic refrigerators. Such systems normally comprise a compartment and a cooling system including an evaporator, a condenser and a compressor. For better controlling the refrigerant flow, the compressor might be a variable speed compressor, which often requires a control system, operating to control the compressor speed.
The need for preserving foodstuff is long known to mankind, considering the large variety of known methods available today. One of these methods would be the ice box, a relatively primitive type of refrigerator, with the purpose of lowering the temperature so as to delay the decomposition process of food. The refrigerator was introduced in the early 19th century consisting of a machine that would use a heat pump to transfer heat from the inside of the compartment to the external environment.
Modern household refrigerators now include a considerable variety of sizes and shapes, such as French Doors, built-in type, side-by-side, with top or bottom freezer, among other varieties. Not only that, but modern refrigerators also present different possible features to adjust temperatures, store different types of foodstuff, auto defrosting settings and many others to make the operation more comfortable for the user.
As the need for new, more sustainable and healthier features increase, the technologies used in such appliances also get more complex. For the last decades, many different technologies have been implemented on domestic refrigerators, and control algorithms are constantly evolving to solve the continuously presented challenges, improving the ways that food can be preserved.
As features get more complex, so does the need for efficiently controlling such features. Moreover, the user can set several inputs on modern refrigerators, specifically focused on controlling the environment inside the appliance such as temperature settings.
Usually, refrigerators are provided with a compartment to accommodate foodstuff, but it is also common to include a second compartment, or even a plurality of compartments with different environment controls. Such compartments frequently require different temperature targets for storing different types of foods (e.g. dairy, eggs, meat, fresh vegetables), so each compartment will naturally need a different cooling load from the cooling system.
For domestic refrigerators, it is a known problem to efficiently control the refrigerant flow throughout the evaporator or evaporators and thereby the control of temperatures in a compartment or compartments to be refrigerated. The need to control said flow is usually related to the different temperature settings set for each compartment in the refrigerator. Naturally, such different temperature settings require different cooling loads for each compartment.
In a particular situation, the compartments comprise two compartments in which a first compartment has a lower temperature in respect to a second compartment. Therefore, the refrigeration system includes the first colder compartment, usually called the freezer compartment, in connection with the second warmer compartment, usually called the fresh food compartment. Under these circumstances, the compressor operation is often regulated through a temperature sensor located in the fresh food compartment. If the temperature sensor determines that there is a need for cooling the fresh food compartment, i.e. if the temperature inside the compartment is too high and might compromise the self-life of refrigerated goods, then the sensor will send a signal to activate the compressor, initiating the cooling process throughout both compartments, regardless whether the freezer compartment also needs cooling.
In some circumstances, the refrigerator is equipped with two evaporators connected in series, a first evaporator being connected to the freezer compartment and a second evaporator being connected to the fresh food compartment. In this particular case, the refrigerant flow path can follow the direction from the first compartment to the second and vice-versa. The flow sequence from the fresh food compartment to the freezer compartment usually requires a valve and a second capillary, as well as a more elaborated control method. In the case of a refrigerant flow path from the freezer compartment to the fresh food compartment the rich refrigerant is initially delivered in the freezer, evaporating and absorbing heat from the freezer compartment. The quantity of refrigerant that evaporates is equivalent to the heat transfer from the freezer compartment which is proportional to the temperature difference between the refrigerant and the compartment air or cooling load.
In the scenario that the refrigerant flow path is from the freezer to the fresh food compartment, once the refrigerant finishes circulating on the first evaporator, the remaining liquid overflows to the second evaporator, where it will finish evaporating and cooling down the refrigerator.
Hence one method to take control over the distribution of cooling load between the freezer and fresh food compartment is to promote an increase in heat transfer from the freezer compartment that would reduce the available refrigerant overflow to the fresh food compartment, consequently reducing cooling in the second compartment (fresh food) and increasing cooling in the first compartment (freezer).
One of the possible ways to manipulate the cooling availability is to have a variable speed compressor in which parameters such as switch control, temperature settings and throughput affect the different speeds for the compressor operation. In the situation where the refrigerant flow path is from the freezer to the fresh food compartment, an increase of the compressor speed consequently increases the heat transfer to the freezer compartment. As the available refrigerant is reduced on the fresh food compartment, the cooling load balance between compartments can be better regulated.
In order to accomplish an efficient control of the cooling system, many known refrigerators have complex control systems, as parameters must be precisely coordinated so that the cooling loads are sufficiently well balanced.
One known solution to this problem is disclosed in WO 2012/150196 A1, presenting a solution in which the targeted throughput of the compressor is controlled, aiming for a higher throughput. However, the solution presented is dependent of common variables actively controlled by the sensors in the compartments, external sensors or duty cycles, which sets a reasonably complex control system.
An improved control method of the compressor is, thus, a constant need for improved operation of such refrigerators.
The invention aims to solve, or at least reduce, the aforementioned problems. A refrigerator achieving this is disclosed in independent claim 1 and improvements of the invention are disclosed in dependant claims 2-10.
According to the invention, a refrigerator comprising a compartment for storing foodstuff is provided. The refrigerator further comprises a cooling system that includes an evaporator, a condenser and a variable speed compressor, and the cooling system is adapted to go through a refrigeration cycle at certain intervals. The refrigeration cycle is hereby referred to as the time period in which the variable speed compressor is active and operating, which implicates that the refrigeration cycle stops once the variable speed compressor is switched off. The time period can be influenced by many parameters and the intervals can be based on time, temperature or any other relevant factors. A control system is provided for controlling the variable speed compressor during the refrigeration cycle and said control system operates in relation to a minimum speed and a required speed. The control system sets a compressor speed, which is understood as the actual compressor speed, according to a comparison between the minimum speed and the required speed. If the minimum speed is lower than the required speed, then the control system will set the compressor speed to the required speed; Otherwise, the control system will set the compressor speed to the minimum speed. Consequently, the control system constantly sets the compressor speed to the highest value of the required speed and the minimum speed.
The refrigerator with such control system is especially advantageous when a minimum speed is set, as it drives the compressor to work at a more efficient speed. In that way, there is a better control of refrigerant flow within the system, reasonably improving energy efficiency. Moreover, by calculating a minimum speed in the way disclosed herein, it is not necessary to provide other external inputs to control the compressor speed, which simplifies this method, providing a good balance of the cooling system without the inherent costs of complexity.
According to some embodiments, the control system might operate in a step-by-step manner.
According to some embodiments, the control system is configured to calculate the minimum compressor speed based on elapsed time from the start of the refrigeration cycle and could further be based on temperature settings. The temperature settings can also be referred to as setpoints, usually set by user input, selecting the preferred temperature for the refrigeration compartments manually, commonly through a display or user interface. The temperature settings could also be a relative position, such as Min/Med/Max or High/Low or a numerical scale. The temperature control inside the compartments might follow common techniques such as PID, Fuzzy or MPC controllers, providing at least one temperature sensor arranged in the compartment with the highest set temperature, but it is also not limited to it. It is advantageous to calculate the minimum compressor speed based on temperature settings as the compressor speed is not actively controlled by cabinet sensors or other inputs besides the temperature settings, which provides the possibility of a better balance of the systems with simpler control.
According to some embodiments, the control system is configured to calculate the required speed through common methods such as the PI control, based specifically on the difference between measured temperature and set temperature, but not limited to it. The required speed might also be determined in other arrangements within the compressor controller without a temperature feedback or any other link to the main control except a switch control for the variable speed compressor.
According to some embodiments, the control system with a switch control is provided. The switch control is configured to start the variable speed compressor at the onset of the refrigeration cycle and stop the variable speed compressor at the end of the cycle. It is advantageous to control the compressor operation routine to increase energy saving for the refrigeration system. The provision of a switch enables to control the compressor in a way that it will remain switched off as long as possible, enabling a more energy efficient set-up.
According to some embodiments, the refrigerator comprises a second compartment. This configuration is especially important in case the compartments are at different temperatures. The presence of two compartments at two different temperatures in a refrigerator indicates that it is usually difficult to control the cooling loads between those compartments. In other words, it is especially hard to keep the desired temperatures in the compartments, requiring an efficient control. The control system described herein is specially adapted to control the compressor speed in a balanced and, thus, more efficient manner. If the compressor speed is well controlled, then it is easier to keep the desired temperatures set by the user. The control system ultimately provides a better refrigerant flow control, according to the pre-determined necessary cooling loads for each compartment.
According to some embodiments, the compartment and the second compartment are connected through a channel, and the cooling system comprises a fan to generate forced air circulation between said compartments. The fan is often arranged in the first compartment, allowing cooled air to be better redistributed using forced air circulation. In this way, the set temperature in the compartments determined by the temperature settings might be reached in a faster and easier way.
According to some embodiments, the cooling system comprises a second evaporator connected in series with the evaporator. One possible and often common configuration provided is that each evaporator is connected to one compartment of the refrigerator. During the refrigeration cycle, the refrigerant must go through the first evaporator on the circuit and then through the second evaporator on the circuit. Such serial configuration creates a direct dependency of the evaporators, requiring an efficient control between the cooling loads demanded by each compartment. If the compressor speed is well controlled by the control system, then the refrigerant flow is more efficiently managed between the evaporators, and it is easier to keep the desired temperatures set by the user in the compartments. The control system ultimately provides a better refrigerant flow control through the evaporators, according to the pre-determined necessary cooling loads for each compartment.
According to some embodiments, the evaporator is connected to the compartment, which is a freezer compartment, and the second evaporator is connected to the second compartment, which is a fresh food compartment, and the flow path of a refrigerant fluid is from the evaporator to the second evaporator. This embodiment is especially advantageous for the invention, as it allows the control system to be more efficient by increasing the compressor speed and, consequently, promoting an increase in heat transfer from the compartment. Such increase corresponds to a reduction of the available refrigerant overflow to the second compartment, consequently reducing the cooling capacity availability in the second compartment and increasing the availability in the first compartment.
A method for the solution discussed herein is disclosed in accordance with the invention in independent method claim 11 and improvements of the invention are disclosed in dependant method claims 12-15.
The method of controlling a variable speed compressor through a control system, the variable speed compressor being in a cooling system of a refrigerator with a compartment, the cooling system being adapted to go through a refrigeration cycle at certain intervals, comprising the steps of:
The method can be visualized by plotting a speed graph during the refrigeration cycle, which ends based on whether the temperature in the compartment reached the desired target according to temperature settings, or other relevant parameters such as the maximum time limit for the variable speed compressor to be active. Moreover, the refrigeration cycle can fluctuate within a great range of intervals, as it can last from minutes up to hours, and there are no pre-set time limits, once the refrigeration cycle varies according to many factors.
Possibly, step (b) is accomplished by considering an elapsed time from the start of the refrigeration cycle and further accomplished by considering temperature settings. It is possible that step (c) is accomplished by considering temperature parameters, specifically the difference between a measured temperature and a set temperature. It is understood that the measured temperature is the reading response from a temperature sensor in a compartment of the refrigerator, while the set temperature is a target temperature introduced by temperature settings.
Further features and advantages of the invention will become clear from the following description of exemplary embodiments with reference to the attached figures.
The invention will, in the following, be described in more detailed referring to the figures wherein:
Considering the field of refrigeration systems, one of the machines commonly found in a household are domestic refrigerators. Such systems comprise a compartment, and a cooling system including an evaporator, a condenser and a compressor. As showed in
A principal sectional side view, with a layout of the interior components, of the refrigerator 100 is shown in
The cooling system 200 in
The refrigerator in
The second compartment 13b includes a temperature sensor 18, and the compartment 13a includes a fan 16 and a channel 15, configured to generate forced air circulation between said compartments. It is possible that the compartments have different temperature settings selected through user input, considering that in this invention the compartment 13a can be referred to as a freezer compartment, and it is set to be in a colder temperature than the second compartment 13b. Thus, the second compartment 13b is the warmer compartment, and can be referred to as a fresh food compartment, in relation to the compartment 13a. It is also possible to select special operation modes through a display 19, which can be any kind of digital or mechanical user interface, including connected devices (internet of things).
It is also provided in
One possible main control 20 operation is showed in
The control system 11 operation is disclosed in
As shown in
Considering the control system 11, it can be described as an algorithm following the steps showed in
Then, the system evaluates if the end of the refrigeration cycle is reached, which is based on whether the temperatures in the compartment 13a and the compartment 13b are within the desired target according to temperature settings, so the compressor must be stopped, ending the refrigeration cycle. If such scenario has not yet been reached, the calculation of steps (a) to (e) shown in
A second embodiment of a refrigerator 110 is shown in
All described features compose an exemplary conventional cooling system 210 with a control system 11, therefore it is possible that other configurations with standard components can be used.
During the refrigeration cycle, regardless of which embodiment of the refrigerator 100, 110 that is considered, several scenarios are possible for the variable speed compressor 10 operation. The control system 11 provided, calculates the minimum speed 36 in relation to at least the elapsed time from the start of the refrigeration cycle and further related to temperature settings. The minimum speed 36 can be active in all operation conditions, not limited to using only said minimum speed 36, as the refrigerator 100, 110 operation may include other operation modes that might increase the compressor speed if necessary. The minimum speed 36 profile is not necessarily controlled actively by compartment sensors or other inputs besides the elapsed time and user input of temperature settings, which provides the possibility of a better balance of this system, with simple temperature control. Considering step (b) of calculating the minimum speed 36,
One possible way of calculating the minimum speed 36 is based on a linear interpolation between values listed on a matrix with time by speed lines, as described above. Hence, from the refrigeration cycle start until a determined time, the speed will linearly move from one speed value to another. The changes of the matrix set by step (b3) are intended to change the temperature difference between the compartment 13a and the second compartment 13b. Naturally, the second compartment 13b, in which the temperature sensor 18 is assembled, possibly has its temperature well defined by such sensor. Thus, in the scenario when the temperature sensor 18 measures the refrigerator 100, 110 temperature, the compartment 13a is indirectly controlled by changing the compressor speed. The ultimate outcome is thus to provide control to the compartment 13a where there was no active control means.
One example of the minimum speed graph plot is represented in
The graph in
In
The required speed 22 might also be determined in other arrangements within the control system 11 without a temperature feedback or any other link to the main control 20 except the switch control 31. This possible calculation for the required speed is based on a duty cycle, which is a function related to elapsed times both from the start and the stop of the refrigeration cycle, meaning an elapsed time from the time the compressor is switched on and an elapsed time from the time the compressor is switched off. The function of the duty cycle is plotted in relation to a matrix related to speed. Naturally, the minimum speed 36 function described in
Such features can also occur in combinations other than those specifically disclosed here. The fact that several characteristics are mentioned in the same sentence or in a different type of textual context does not therefore justify the conclusion that they can only occur in the specifically disclosed combination, instead, it can generally be assumed that several of these characteristics can also be omitted or modified, provided that the functionality of the invention is not modified.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/057939 | 3/26/2021 | WO |