SYSTEM AND METHOD FOR POSITIONING A SLIDER OF A REVERSING VALVE

Information

  • Patent Application
  • 20210156596
  • Publication Number
    20210156596
  • Date Filed
    November 19, 2020
    3 years ago
  • Date Published
    May 27, 2021
    3 years ago
Abstract
A system and method for positioning a slider of a reversing valve. A method includes receiving a command for operating a reversing valve in a first mode, a second mode or a third mode. The reversing valve comprises a first tube, a second tube, a third tube, and a fourth tube. The method further describes determining a tonnage profile for refrigerant to flow in the reversing valve. The method further describes communicating the command and the tonnage profile to a stepper motor and linearly moving a lead screw based on the command and the tonnage profile to position a slider on the second tube and the third tube in the second mode and the third mode or on the third tube and the fourth tube in the first mode.
Description
FOREIGN PRIORITY

This application claims priority to Indian Patent Application No. 201911048669, filed Nov. 27, 2019, and all the benefits accruing therefrom under 35 U.S.C. § 119, the contents of which in its entirety are herein incorporated by reference.


TECHNICAL FIELD

The present invention generally relates to heat pumps. More particularly, the invention relates to a system and a method for positioning a slider of a reversing valve in the heat pumps.


BACKGROUND

In earlier times, a heater device was used to heat up a particular area/room in winters and a cooler device was used for cooling the same area in summers. The heater device and the cooler device had to be separately bought and installed in the same area to perform separate functioning. With the developments in the technology, heat pumps were developed that can be used for heating as well as cooling the same area.


In order to use the same heat pump for heating operation, defrosting operation as well as cooling operation, a reversible valve is used in the heat pumps that can perform heating, defrosting, and cooling operations one at a time. Such reversible valve eliminates the requirement of using separate devices for heating, defrosting and cooling operations. In particular, the reversible valve has a solenoid valve to shift the reversible valve for reversing the operation. However, the solenoid valve needs to energized all the time based on required operation thereby, resulting in wastage of energy. Further, the solenoid valve relies upon optimal pressure differential between high and low sides of the heat pump that can be unreliable in some systems. Furthermore, the reversible valve sometimes fails to shift from the heating operation to cooling operation or vice-versa, or from defrosting operation to heating operation and does not completely reverse the operation. Moreover, the reversible valve also suffers leakage while reversing operation. In addition, only one reversing valve can be used for each tonnage.


In view of the afore-mentioned problems in the existing reversible valve, there is a need of an efficient and effective system and method for eliminating the requirement of energizing a valve for both cooling, defrosting and heating operations. There is also a need of a valve that completely reverses an operation. There is also a need of a valve that does not fail to shift the operation. In order to solve problems in the existing reversible valve, a system and a method are disclosed.


SUMMARY

Various embodiments of the invention describe a system for positioning a slider of a reversing valve in heat pump/s. The system comprises a reversing valve adapted to operate in a first mode, a second mode or a third mode. Further, the reversing valve comprises a first tube, a second tube, a third tube and a fourth tube. The system also comprises a control board adapted to receive a command for operating the reversing valve in the first mode, the second mode or the third mode and determine a tonnage profile for refrigerant to flow in the reversing valve. Also, the refrigerant flows in a first flow in the first mode or in a second flow in the second mode or in the second flow in the third mode. The control board is adapted to communicate the command and the tonnage profile for the refrigerant to a stepper motor. The stepper motor is adapted to linearly move a lead screw based on the command and the tonnage profile to position a slider on the second tube and the third tube in the second mode or on the third tube and the fourth tube in the first mode or on the second tube and the third tube in the third mode.


In an embodiment of the invention, the tonnage profile for refrigerant is determined based on a temperature defined by a user.


In another embodiment of the invention, the slider is variably positioned at a first position for a first tonnage profile, at a second position for a second tonnage profile and/or at a third position for a third tonnage profile.


In yet another embodiment of the invention, the stepper motor is adapted to perform a first number of steps for positioning the slider at a first position, a second number of steps for positioning the slider at a second position and/or a third number of steps for positioning the slider at a third position.


In another embodiment of the invention, the stepper motor is adapted to determine an incorrect position of the slider based on a current location of the slider, wherein the control board is adapted to verify the incorrect position of the slider with respect to a programmed location of the slider and is adapted to provide a command to the stepper motor to move the slider to a desired location.


In still another embodiment of the invention, the lead screw is linearly moved in an inward direction in the second mode or the third mode to position the slider on the second tube and the third tube.


In a different embodiment of the invention, the lead screw is linearly moved in an outward direction in the first mode to position the slider on the third tube and the fourth tube.


In yet another embodiment of the invention, the first mode is a heating mode and the second mode is a cooling mode and the third mode is a defrost mode.


In another embodiment of the invention, the first tube is a compressor discharge tube. Also, the first tube is positioned at a first surface of the reversing valve.


In an embodiment of the invention, the second tube, the third tube, and the fourth tube are positioned at a second surface of the reversing valve.


In yet another embodiment of the invention, the second tube acts as a condenser tube, the third tube acts as a compressor return tube, and the fourth tube acts as an evaporator tube in the first mode.


In another embodiment of the invention, the second tube acts as an evaporator tube, the third tube acts as a compressor return tube, and the fourth tube acts as a condenser tube in the second mode and/or in the third mode.


In still another embodiment of the invention, the second tube is connected to an indoor unit and the fourth tube is connected to an outdoor unit in the first mode, in the second mode and/or in the third mode.


In a different embodiment of the invention, the refrigerant flows from a compressor to the first tube, from the first tube to the second tube and from the second tube to an indoor unit in the first flow. Further, the refrigerant flows from a compressor to the first tube, from the first tube to the fourth tube and from the fourth tube to an outdoor unit in the second flow.


In an embodiment of the invention, the slider is a C-shaped slider or a U-shaped slider.


Various embodiments of the invention describe a method for positioning a slider of a reversing valve in heat pump/s. The method comprises the step of receiving by a control board, a command for operating a reversing valve in a first mode, a second mode or a third mode. The reversing valve comprises a first tube, a second tube, a third tube and a fourth tube. The method also comprises the step of determining by the control board, a tonnage profile for refrigerant to flow in the reversing valve. Also, the refrigerant flows in a first flow in the first mode or in a second flow in the second mode and in the second flow in the third mode. The method further comprises the step of communicating the command and the tonnage profile for refrigerant to a stepper motor. Accordingly, the stepper motor linearly moves a lead screw based on the command and the tonnage profile to position a slider on the second tube and the third tube in the second mode or on the third tube and the fourth tube in the first mode or on the second tube and the third tube in the third mode.


In another embodiment of the invention, the slider is variably positioned at a first position for a first tonnage profile, at a second position for a second tonnage profile and/or at a third position for a third tonnage profile.


In yet another embodiment of the invention, the lead screw is linearly moved in an inward direction in the second mode or in the third mode to position the slider on the second tube and the third tube and the lead screw is linearly moved in an outward direction in the first mode to position the slider on the third tube and the fourth tube.


In still another embodiment of the invention, the first mode is a heating mode, the second mode is a cooling mode and the third mode is a defrost mode.


This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.


Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1A depicts an assembled view of an exemplary reversing valve and FIG. 1B depicts an exploded view of the exemplary reversing valve according to an exemplary embodiment of the invention.



FIG. 1C depicts a top view of an exemplary flow diverter of a reversing valve, FIG. 1D depicts a cross-sectional front view of the exemplary flow diverter, FIG. 1E depicts a bottom view of the exemplary flow diverter, FIG. 1F depicts a side view of the exemplary flow diverter, and FIG. 1G depicts a cross-sectional front view of the exemplary reversing valve, according to an exemplary embodiment of the invention.



FIG. 2 depicts an exemplary system architecture with a reversing valve operating in a first mode according to an exemplary embodiment of the invention.



FIG. 3 depicts an exemplary system architecture with a reversing valve operating in a second mode or in a third mode according to an exemplary embodiment of the invention.



FIG. 4A depicts an exemplary first position of a slider for a first tonnage profiles in a first mode, FIG. 4B depicts an exemplary second position and third position of a slider for a second or third tonnage profiles in a first mode, FIG. 4C depicts an exemplary first position of a slider for a first tonnage profiles in a second mode, and FIG. 4D depicts an exemplary second position and third position of a slider for a second or third tonnage profiles in a second mode according to an exemplary embodiment of the invention.



FIG. 5 depicts an exemplary flowchart illustrating a method to perform the invention according to an exemplary embodiment of the invention.





Corresponding reference numerals indicate corresponding parts throughout the drawings.


DETAILED DESCRIPTION

Described herein is the technology with a system and a method for positioning a slider of a reversing valve in heat pump/s. The reversing valve may comprise a first tube, a second tube, a third tube and a fourth tube. The reversing valve may be connected with a compressor, an indoor unit and an outdoor unit through one or more tubes. Further, the reversing valve may operate either in a first mode or in a second mode or in a third mode based on a command. The command may be provided by a user through a thermostat for operating the reversing valve in the first mode or in the second mode or in the third mode. The command may be received by a control board and the control board may determine a tonnage profile for refrigerant to flow through the reversing valve. Based on the command and the tonnage profile for refrigerant, a stepper motor moves a lead screw to position a slider on the second tube and the third tube when the reversing valve operates in the second mode or on the third tube and the fourth tube when the reversing valve operates in the first mode or on the second tube and on the third tube when the reversing valve operates in the third mode. In specific, the stepper motor may be programmed in such a way that the stepper motor moves the lead screw linearly to place the slider at various positions based on the tonnage profile for refrigerant in the first mode or the second mode or the third mode.


As used herein, the reversing valve may be adapted to control a flow of refrigerant through the reversing valve based on the first mode or the second mode or the third mode. The first mode may be a heating mode and the second mode may be a cooling mode and third mode may be a defrost mode. When the reversing valve operates in the first mode, the refrigerant flows in a first flow and when the reversing valve operates in the second mode, the refrigerant flows in a second flow and when the reversing valve operates in the third mode, the refrigerant flows in the second flow. The details of flow of the refrigerant in the reversing valve operating in the first mode or the second mode or the third mode have been explained in detail below. The reversing valve may be any slide-type reversing valve that is well known in the art. When the reversing valve is used in variable speed units and at variable flows, the tonnage profile may vary.


As used herein, the control board may be an electronic circuitry or a printed circuit board communicably coupled and/or attached with the reversing valve and/or a thermostat. The control board may be present outside the reversing valve. The control board may also be communicably coupled with the thermostat to receive a command. The command may be provided by a user to operate the reversing valve either in the first mode or the second mode or the third mode. The control board may further be communicably coupled and/or attached with a stepper motor.


As used herein, the stepper motor may be communicably coupled and/or attached with the reversing valve and or the control board. The stepper motor may be present outside the reversing valve. Further, the stepper motor may be programmed in such a way that the stepper motor may move a lead screw inside the reversing valve to position a slider. The stepper motor may be any stepper motor that is well known in the art.



FIG. 1A depicts an assembled view 100A of an exemplary reversing valve 102 according to an exemplary embodiment of the invention. As depicted in FIG. 1A, the reversing valve 102 may have a first surface 104 and a second surface 108. Further, the reversing valve 102 may comprise a first tube 106, a second tube 110, a third tube 112, and a fourth tube 114. As can be seen, the first tube 106 may be positioned at the first surface 104 of the reversing valve 102. Also, the second tube 110, the third tube 112, and the fourth tube 114 may be positioned at the second surface 108 of the reversing valve 102. The reversing valve 102 also comprises a stepper motor 118 and a lead screw 120 to position a slider (not shown) on any two tubes of the reversing valve 102. Also, a mount 138 for attaching the stepper motor may be connected or attached with the reversing valve 102.



FIG. 1B depicts an exploded view 100B of the exemplary reversing valve 102 according to an exemplary embodiment of the invention. In this exploded view 100B, the reversing valve 102 comprises a stepper motor 118, a lead screw 120 communicably coupled with the stepper motor 118, a mount 138 for the stepper motor 118 and attached with the reversing valve 102, a nut 136 for the lead screw 120, a flow diverter 134 to divert or guide refrigerant in the reversing valve 102, a cap 140 to enclose/cover a side of the reversing valve 102 and a pin 142 to be inserted in the cap 140. The flow diverter 134 may be inserted inside the reversing valve 102.



FIG. 1C depicts a top view of an exemplary flow diverter 134 of a reversing valve 102 according to an exemplary embodiment of the invention. In this top view, a first mode tube and a second mode tube can be seen. The first mode tube of the flow diverter 134 may be used when the reversing valve 102 operates in a first mode. Similarly, the second mode tube of the flow diverter 134 may be used when the reversing valve 102 operates in a second mode. The first mode tube and the second mode tube of the flow diverter 134 may be used to make the refrigerant flow in the reversing valve 102 as per the mode in which the reversing valve 102 is operating.



FIG. 1D depicts a cross-sectional front view of the exemplary flow diverter 134 according to an exemplary embodiment of the invention. In this cross-sectional front view, along with the first mode tube and the second mode tube of the flow diverter 134, a slider 116 can be seen. Further, the slider 116 may be positioned on any two tubes of the reversing valve 102 as per the mode in which the reversing valve 102 is operating. This has been discussed in details in FIG. 2 and FIG. 3 below.



FIG. 1E depicts a bottom view of the exemplary flow diverter 134 according to an exemplary embodiment of the invention. In this bottom view, the first mode tube and the second mode tube may be positioned at two opposite extreme ends of the flow diverter 134. Also, the slider 116 may be present in between the first mode tube and the second mode tube of the flow diverter 134 in the reversing valve 102.



FIG. 1F depicts a side view of the exemplary flow diverter 134, according to an exemplary embodiment of the invention. The side view of the flow diverter 134 has a pin and the cap 140 (as shown in FIG. 1B) may be used to cover the side view of the exemplary flow diverter 134. FIG. 1G depicts a cross-sectional front view of the exemplary reversing valve 102, according to an exemplary embodiment of the invention.



FIG. 2 depicts exemplary system architecture 200 with a reversing valve 102 operating in a first mode according to an exemplary embodiment of the invention. Based on a mode of operation of the reversing valve 102, the stepper motor 118 may accordingly move the lead screw 120 to position the slider 116 on any two tubes of the reversing valve 102. Moreover, as depicted, a thermostat 130 and/or the indoor unit 124 may be placed inside a building/home 128. The indoor unit 124 may be adapted to provide heating inside the building/home 128.


A user (not shown) may select an option in the thermostat 130 to operate the reversing valve 102 in a first mode. For this, the user may use a soft button or hard button provided in an interface of the thermostat 130 to give a command for operating the reversing valve 102 in the first mode. In an exemplary embodiment, the first mode may be a heating mode. Before the user provides the command, heat pump of the reversing valve 102 may be powered-on for starting its functioning or the reversing valve 102 was already operating in a cooling mode (i.e. a second mode) and may provide a command for mode reversal. In an exemplary embodiment, the command provided by the user may be G-code commands that are used in real time to build a system with dynamic behavior to have precise movements to a lead screw. When the user provides the command, the thermostat 130 may transmit the command to a control board 132 through a wired network or a wireless network. The control board 132 may be communicably coupled or attached with the thermostat 130 and the reversing valve 102. The control board 132 may be present inside or outside the building/home 128.


When the control board 132 receives the command from the thermostat 130 to operate the reversing valve 102 in the first mode, the control board 132 may determine a tonnage profile for refrigerant to flow in the reversing valve 102. For this, the tonnage profile for refrigerant is determined by the control board 132 based on a temperature defined by the user and/or a temperature inside the building/home 128. In specific, the user may define the temperature based on number of people/occupants present in the building/home 128. For an instance, the user may vary the tonnage by varying the refrigerant for a 3 tons heat pump with only one occupant in the building/home 128. If there are multiple occupants in the building/home 128 which may exceed temperature, then the system 100 may decide to run at full load condition, depending upon the heat generated by multiple occupants the building/home 128. In an exemplary embodiment, the control board 132 may request the thermostat 130 to provide a current temperature inside the building/home 128. In another exemplary embodiment, the control board 132 may determine a current temperature inside the building/home 128. In another exemplary embodiment, the tonnage profile for the refrigerant may be determined based on a product number and a type of the control board 132. For an instance, if the product number is 24ABB360A0000101, the tonnage profile will be 3 Ton unit. Also, by using the control board 132 of 3 tons with variable speed, then the 3 Ton unit may be downgraded to function as 2.5 T, 2 T and 1.5 T etc. Furthermore, the 3 Ton control board 132 can only work under full load condition and cannot be upgrade to next higher tonnages. In other words, the control selected for 3 T will be very specific to 3 T and for down-gradable tonnages only.


After the control board 132 determines the current temperature inside the building/home 128, the control board 132 may accordingly determine a tonnage profile for the refrigerant to flow into the reversing valve 102. The control board 132 may determine a first tonnage profile, a second tonnage profile or a third tonnage profile. The control board 132 may determine the first tonnage profile when a difference between the current temperature inside the building/home 128 and a pre-defined heating temperature threshold is low. Similarly, the control board 132 may determine the second tonnage profile when a difference between the current temperature inside the building/home 128 and a pre-defined heating temperature threshold is nominal. Likewise, the control board 132 may determine the third tonnage profile when a difference between the current temperature inside the building/home 128 and a pre-defined heating temperature threshold is high. Then, the control board 132 may communicate the command to operate the reversing valve 102 in the first mode and the determined tonnage profile to the stepper motor 118. In an exemplary embodiment, the pre-defined heating temperature threshold may be defined by the user of the thermostat 130 and may be the temperature that is desired to be maintained inside the building/home 128.


When the stepper motor 118 receives the command and the determined tonnage profile, the stepper motor 118 may linearly move the lead screw 120 based on the command and the tonnage profile. In particular, the stepper motor 118 may be programmed in such a manner that the stepper motor 118 may move the lead screw 120 to position the slider 116 at a first position when the control board 132 determines the first tonnage profile. Likewise, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a second position when the control board 132 determines the second tonnage profile. Also, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a third position when the control board 132 determines the third tonnage profile. This embodiment of the present invention provides a technical advantage of eliminating the requirement of continuously energizing a valve for heating and providing complete reversal of from cooling mode to heating mode. Also defrosting mode, when control board 132 sends command, when desired.


In an exemplary embodiment, the slider 116 may be a C-shaped slider or a U-shaped slider or any such shape that offers lesser pressure drop and/or smooth flow. Further, in the first mode and as depicted in FIG. 2, the first tube 106 of the reversing valve 102 may be connected with a discharge port of a compressor 122. The second tube 110 may be connected with an indoor unit 124, the third tube 112 may be connected with a return port of a compressor 122 and the fourth tube 114 may be connected with an outdoor unit 126. Furthermore, in the first mode, the stepper motor 118 may move the lead screw 120 to position the slider 116 on the third tube 112 and the fourth tube 114 as shown in FIG. 2. Also, the stepper motor 118 may linearly move the lead screw 120 in an outward direction from the reversing valve 102 to position the slider 116 on the third tube 112 and the fourth tube 114. The determination of the tonnage profile and the positioning of the slider 116 with respect to the tonnage profile have been explained in greater details below with examples in exemplary Table 1 and also depicted in FIG. 4A and FIG. 4B below.









TABLE 1







Heating Mode












Current
Pre-defined



Opening of


Temperature
Heating



each tube in


Inside
Temperature
Tonnage
Flow of
Position of
millimeters (mm)


Building
threshold
Profile
Refrigerant
Slider
by moving Slider





24° Celsius
30° Celsius
First
1.5 tons to
First
12 mm opening




Tonnage
2 tons
Position
for each tube




Profile


12° Celsius
30° Celsius
Second
3 tons to
Second
12 mm opening




Tonnage
4 tons
Position
for first tube




Profile


106 and 17.21







mm opening for







other tubes







110, 112, 114


2° Celsius
30° Celsius
Third
5 tons
Third
12 mm opening




Tonnage

Position
for first tube




Profile


106 and 17.21







mm opening for







other tubes







110, 112, 114









As can be seen in Table 1 above, the first tonnage profile may be determined when the difference between the current temperature (i.e. 24° Celsius) inside the building/home 128 and the pre-defined heating temperature threshold (i.e. 30° Celsius) is low (i.e. 6° Celsius). For the first tonnage profile, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a first position on the third tube 112 and the fourth tube 114. At the first position, the stepper motor 118 may move the lead screw 120 to open each tube 106, 110, 112, 114 by 12 mm so that the refrigerant may flow at the volume of 1.5 tons to 2 tons. Further, the second tonnage profile may be determined when the difference between the current temperature (i.e. 12° Celsius) inside the building/home 128 and the pre-defined heating temperature threshold (i.e. 30° Celsius) is nominal (i.e. 18° Celsius). For the second tonnage profile, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a second position on the third tube 112 and the fourth tube 114. At the second position, the stepper motor 118 may move the lead screw 120 to open first tube 106 by 12 mm and to open the second tube 110, the third tube 112 and the fourth tube 114 by 17.21 mm so that the refrigerant may flow at the volume of 3 tons to 4 tons. Moreover, the third tonnage profile may be determined when the difference between the current temperature (i.e. 2° Celsius) inside the building/home 128 and the pre-defined heating temperature threshold (i.e. 30° Celsius) is high (i.e. 28° Celsius). For the third tonnage profile, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a third position on the third tube 112 and the fourth tube 114. At the third position, the stepper motor 118 may move the lead screw 120 to open first tube 106 by 12 mm and to open the second tube 110, the third tube 112 and the fourth tube 114 by 17.21 mm so that the refrigerant may flow at the volume of 5 tons. By determining the tonnage profile, this embodiment of the present invention provides a technical advantage of precise/fine positioning of the slider 116 on the on third tube 112 and the fourth tube 114 using the programmed stepper motor 118 and varying the flow of the refrigerant. Such variations in positioning of the slider 116 on the third tube 112 and the fourth tube 114 may help in effective heating inside the building/home 128. Various other variations in positioning the slider and relative movement of the lead screw are within the scope of the invention. In specific, the movement of the lead screw 120 may be linear with the movement of the slider 116. Moreover, the openings of the tube for variable speed and variable flow units for 1.5 T to 2 T, the variable flow rate will be 50%, 60% and 70% opening, whereas for the opening for variable speed and variable flow units for 3 T to 5 T, the variable flow rate will be 50%, 60% and 70% opening.


Based on the tonnage profile and the command, the refrigerant may move in a first flow when the reversing valve 102 operates in the first mode. In particular, the refrigerant may discharge from the discharge port of the compressor 122 at a high pressure and may flow/enter in the first tube 106 of the reversing valve 102. In an exemplary embodiment, the first tube 106 may act as a compressor discharge tube when the refrigerant enters in the first tube 106 from discharge port of the compressor 122. From the first tube 106, the refrigerant may flow to the second tube 110 as the slider 116 is placed on the third tube 112 and the fourth tube 114. In an exemplary embodiment, the second tube 110 may act as a condenser tube. From the second tube 110, the refrigerant may flow to the indoor unit 124 and then may pass to the outdoor unit 126. In an exemplary embodiment, the outdoor unit 126 may be an evaporator that converts the refrigerant from a liquid state to a gaseous state. From the outdoor unit 126, the refrigerant may enter the fourth tube 114 and then from the fourth tube 114, the refrigerant may enter to the third tube 112 through the slider 116. In an exemplary embodiment, the fourth tube 114 may act as an evaporator tube as the refrigerant gets evaporated. Then the refrigerant may exit the third tube 112 and may go back to the return port of the compressor 122. In an exemplary embodiment, the third tube 112 acts as a compressor return tube as the refrigerant returns to the compressor 122.



FIG. 3 depicts exemplary system architecture 300 with a reversing valve 102 operating in a second mode according to an exemplary embodiment of the invention. A user (not shown) may select an option in the thermostat 130 to operate the reversing valve 102 in the second mode or in the third mode. For this, the user may use a soft button or hard button provided in an interface of the thermostat 130 to give a command for operating the reversing valve 102 in the second mode or in the third mode. In an exemplary embodiment, the second mode may be a cooling mode and the third mode may be defrost mode. Before the user provides the command, heat pump of the reversing valve 102 may be powered-on for starting its functioning or the reversing valve 102 was already operating in a heating mode (i.e. a first mode) and may provide a command for mode reversal. When the user provides the command, the thermostat 130 may transmit the command to the control board 132 through a wired network or a wireless network.


When the control board 132 receives the command from the thermostat 130 to operate the reversing valve 102 in the second mode or in the third mode, the control board 132 may determine a tonnage profile for the refrigerant to flow in the reversing valve 102. For this, the tonnage profile for refrigerant is determined by the control board 132 based on a temperature inside building/home 128 and/or a temperature set by the user. The control board 132 may determine a current temperature inside building/home 128 as explained in FIG. 2 above. After the control board 132 determines the current temperature inside the building/home 128, then the control board 132 may accordingly determine a tonnage profile for refrigerant to flow in the reversing valve 102. The control board 132 may determine a first tonnage profile, a second tonnage profile or a third tonnage profile. The control board 132 may determine the first tonnage profile when a difference between the current temperature inside the building/home 128 and a pre-defined cooling temperature threshold is low. Similarly, the control board 132 may determine the second tonnage profile when a difference between the current temperature inside the building/home 128 and a pre-defined cooling temperature threshold is nominal. Likewise, the control board 132 may determine the third tonnage profile when a difference between the current temperature inside the building/home 128 and a pre-defined cooling temperature threshold is high. Then, the control board 132 may communicate the command to operate the reversing valve 102 in the second mode and the determined tonnage profile to the stepper motor 118. In an exemplary embodiment, the pre-defined cooling temperature threshold may be defined by the user of the thermostat 130 and may be the temperature that is desired to be maintained inside the building/home 128.


When the stepper motor 118 receives the command and the determined tonnage profile, the stepper motor 118 may linearly move the lead screw 120 based on the command and the tonnage profile. In particular, the stepper motor 118 may be programmed in such a manner that the stepper motor 118 may move the lead screw 120 to position the slider 116 at a first position when the control board 132 determines the first tonnage profile, at a second position when the control board 132 determines the second tonnage profile and a third position when the control board 132 determines the third tonnage profile. Furthermore, in the second mode or in the third mode, the stepper motor 118 may move the lead screw 120 to position the slider 116 on the second tube 110 and the third tube 112. Also, the stepper motor 118 may linearly move the lead screw 120 in an inward direction (as shown in FIG. 3) from the reversing valve 102 to position the slider 116 on the second tube 110 and the third tube 112. As depicted in FIG. 3, in the second mode or in the third mode of the reversing valve 102, the first tube 106 of the reversing valve 102 may be connected with a discharge port of a compressor 122, the second tube 110 may be connected with the indoor unit 124, the third tube 112 may be connected with the a return port of the compressor 122, and the fourth tube 114 may be connected with the outdoor unit 126. This embodiment of the present invention provides a technical advantage of eliminating the requirement of continuously energizing a valve for cooling and providing complete reversal from heating mode to cooling mode or to defrost mode. The determination of the tonnage profile and the positioning of the slider 116 with respect to the tonnage profile in the second mode or in the third mode have been explained in greater details in exemplary Table 2 below and also depicted in FIG. 4C and FIG. 4D below.









TABLE 2







Cooling Mode or Defrost Mode












Current
Pre-defined



Opening of


Temperature
Cooling



each tube in


inside
Temperature
Tonnage
Flow of
Position of
millimeters (mm)


Building
threshold
Profile
Refrigerant
Slider
by moving slider





22° Celsius
18° Celsius
First
1.5 tons to
First
12 mm opening




Tonnage
2 tons
Position
for each tube




Profile


30° Celsius
18° Celsius
Second
3 tons to
Second
12 mm opening




Tonnage
4 tons
Position
for first tube




Profile


106 and 17.21







mm opening for







other tubes







110, 112, 114


40° Celsius
18° Celsius
Third
5 tons
Third
12 mm opening




Tonnage

Position
for first tube




Profile


106 and 17.21







mm opening for







other tubes







110, 112, 114









As can be seen in Table 2 above, the first tonnage profile may be determined when the difference between the current temperature (i.e. 22° Celsius) inside the building/home 128 and the pre-defined cooling temperature threshold (i.e. 18° Celsius) is low (i.e. 4° Celsius). For the first tonnage profile, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a first position on the second tube 110 and the third tube 112. At the first position, the stepper motor 118 may move the lead screw to open each tube 106, 110, 112, 114 by 12 mm so that the refrigerant may flow at the volume of 1.5 tons to 2 tons. Further, the second tonnage profile may be determined when the difference between the current temperature (i.e. 30° Celsius) inside the building/home 128 and the pre-defined cooling temperature threshold (i.e. 18° Celsius) is nominal (i.e. 12° Celsius). For the second tonnage profile, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a second position on the second tube 110 and the third tube 112. At the second position, the stepper motor 118 may move the lead screw 120 to open first tube 106 by 12 mm and to open the second tube 110, the third tube 112 and the fourth tube 114 by 17.21 mm so that the refrigerant may flow at the volume of 3 tons to 4 tons. Moreover, the third tonnage profile may be determined when the difference between the current temperature (i.e. 40° Celsius) inside the building/home 128 and the pre-defined cooling temperature threshold (i.e. 18° Celsius) is high (i.e. 22° Celsius). For the third tonnage profile, the stepper motor 118 may move the lead screw 120 to position the slider 116 at a third position on the second tube 110 and the third tube 112. At the third position, the stepper motor 118 may move the lead screw 120 to open first tube 106 by 12 mm and to open the second tube 110, the third tube 112 and the fourth tube 114 by 17.21 mm so that the refrigerant may flow at the volume of 5 tons. By determining the tonnage profile, this embodiment of the present invention provides a technical advantage of precise/fine positioning of the slider 116 on the second tube 110 and the third tube 112 using the programmed stepper motor 118 and varying the flow of the refrigerant. Such variations in positioning of the slider 116 on the second tube 110 and the third tube 112 may help in effective cooling inside the building/home 128. In specific, the movement of the lead screw 120 may be linear with the movement of the slider 116.


Based on the tonnage profile and the command, the refrigerant may move in a second flow when the reversing valve 102 operates in the second mode or in the third mode. In particular, the refrigerant may discharge from the discharge port of the compressor 122 at a high pressure and may flow/enter in the first tube 106 of the reversing valve 102. In an exemplary embodiment, the first tube 106 may act as a compressor discharge tube as the refrigerant enters in the first tube 106 from discharge port of the compressor 122. From the first tube 106, the refrigerant may flow to the fourth tube 114 as the slider 116 is placed on the second tube 110 and the third tube 112. The indoor unit 124 may be adapted to provide cooling inside the building/home 128. In an exemplary embodiment, the outdoor unit 126 may be a condenser that converts the refrigerant from a gaseous state to a liquid state. From the indoor unit 124, the refrigerant may enter the second tube 110 and then to the third tube 112 through the slider 116. In an exemplary embodiment, the second tube 110 may act as an evaporator tube as the refrigerant gets evaporated. Then, the refrigerant may exit through the third tube 112 and may goes back to the return port of the compressor 122. In an exemplary embodiment, the third tube 112 may act as a compressor return tube as the refrigerant returns to the compressor 122.


The present invention encompasses the stepper motor 118 to be programmed in such a way that the positioning of the slider 116 using the lead screw 120 is done in number of steps per revolution as performed by the stepper motor 118. For this, the number of steps per revolution to be performed/taken by the stepper motor 118 to position the slider 116 may be programmed. The stepper motor 118 may be programmed to perform/take a first number of steps for positioning the slider 116 at the first position, a second number of steps for positioning the slider 116 at the second position and/or a third number of steps for positioning the slider 116 at the third position. For an instance, the stepper motor 118 may be programmed to take 50 number of steps to position the slider 116 at first position to open 12 mm diameter of each of the tubes. Also, the stepper motor 118 may be programmed to take 120 number of steps to position the slider 116 at second position open 17.21 mm diameter of the three tubes 110, 112, 114. Then, the stepper motor 118 may be programmed to take 200 number of steps to position the slider 116 at third position.


The present invention further encompasses the stepper motor 118 and/or the control board 132 may determine an error associated with the movement/position of the slider 116. For this, the stepper motor 118 and/or the control board 132 may determine an incorrect position of the slider 116 based on a current location (or co-ordinates) of the slider 116 on each of the tubes. Further, the stepper motor 118 may communicate the incorrect position of the slider 116 to the control board 132. The control board 132 may verify the incorrect position of the slider 116 by comparing the incorrect position to a programmed location of the slider 116. In an exemplary embodiment, the programmed location of the slider 116 is already preprogrammed or configured in the control board 132. Accordingly, the control board 132 may provide a command to the stepper motor 118 to move the slider 116 to a desired location based on the comparison. This would help in error correction of the position of the slider 116 with respect to the programmed location of the slider 116. Moreover, the logs of error correction and position of the slider 116 with respect to the programmed location may be captured/stored by the control board 132 for error control and diagnostics purpose.


Although a limited number of tonnage profiles (i.e. 3 tonnage profiles) and slider positions (i.e. 3 positions) have been explained herein in the specification for both the first mode, the second mode or in the third mode, however, any number and any other possible variations/alterations in the tonnage profiles and slider positions are within the scope of this invention. Moreover, the movement/positioning of the slider on the tubes at several different positions is not only limited to centimeters or percentage, but any other possible variations/alterations for movement/positioning of the slider on the tubes at several different positions are within the scope of this present invention. As used herein, the definition of the terms “low”, “nominal” and “high” in the first mode as well as in the second mode may vary from case to case and in each scenario. The choice of deciding whether a difference between a pre-defined temperature threshold (for cooling or heating) and a current temperature inside the building/home 128 is “low”, “nominal” and “high” resides with the control board 132. In an exemplary embodiment, the control board 132 may decide that a difference between a pre-defined temperature threshold (for cooling or heating) and a temperature inside the building/home 128 is “low” when such a temperature difference lies in the range of 2° Celsius to 8° Celsius. Similarly, the control board 132 may decide that a difference between a pre-defined temperature threshold (for cooling or heating) and a current temperature inside the building/home 128 is “nominal” when such a temperature difference lies in the range of 9° Celsius to 20° Celsius. Likewise, the control board 132 may decide that a difference between a pre-defined temperature threshold (for cooling or heating) and a current temperature inside the building/home 128 is “high” when such a temperature difference lies in the range of 21° Celsius to 35° Celsius. It is to be noted that the temperature ranges and the pre-defined temperature threshold (for cooling or heating) provided herein are exemplary and any other possible variations/alterations in the temperature ranges as well as the defined temperature threshold are within the scope of this invention.



FIG. 4A depicts an exemplary first position of a slider 116 for a first tonnage profiles in a first mode. As explained in FIG. 2 and Table 1 above, when the reversing valve 102 operates in the first mode, the slider 116 may be positioned at a first position in the first tonnage profile. As can be seen in FIG. 4A, in the first mode of the reversing valve 102, the slider 116 may be positioned on the third tube 112 and the fourth tube 114 at the first position such that each tube (i.e. the first tube 106, the second tube 110, the third tube 112 and the fourth tube 114) have an opening of 12 millimeters to pass the refrigerant.



FIG. 4B depicts an exemplary second position and third position of a slider 116 for a second or third tonnage profiles in a first mode. As explained in FIG. 2 and Table 1 above, when the reversing valve 102 operates in the first mode, the slider 116 may be positioned at a second position and/or a third position in the second tonnage profile and/or third tonnage profile. As can be seen in FIG. 4B, in the first mode of the reversing valve 102, the slider 116 may be positioned on the third tube 112 and the fourth tube 114 at the second position and/or the third position such that first tube 106 has an opening of 12 millimeters and other tubes (i.e. the second tube 110, the third tube 112 and the fourth tube 114) have an opening of 17.21 millimeters in order to pass the refrigerant.



FIG. 4C depicts an exemplary first position of a slider 116 for a first tonnage profiles in a second mode or a third mode. As explained in FIG. 3 and Table 2 above, when the reversing valve 102 operates in the second mode or the third mode, the slider 116 may be positioned at a first position in the first tonnage profile. As can be seen in FIG. 4C, in the second mode or the third mode of the reversing valve 102, the slider 116 may be positioned on the second tube 110 and the third tube 112 at the first position such that each tube (i.e. the first tube 106, the second tube 110, the third tube 112 and the fourth tube 114) have an opening of 12 millimeters to pass the refrigerant.



FIG. 4D depicts an exemplary second position and third position of a slider 116 for a second or third tonnage profiles in a second mode or a third mode according to an exemplary embodiment of the invention. As explained in FIG. 3 and Table 2 above, when the reversing valve 102 operates in the second mode or third mode, the slider 116 may be positioned at a second position and/or a third position in the second tonnage profile and/or third tonnage profile. As can be seen in FIG. 4D, in the second mode or the third mode of the reversing valve 102, the slider 116 may be positioned on the second tube 110 and the third tube 112 at the second position and/or the third position such that first tube 106 has an opening of 12 millimeters and other tubes (i.e. the second tube 110, the third tube 112 and the fourth tube 114) have an opening of 17.21 millimeters in order to pass the refrigerant.



FIG. 5 depicts a flowchart outlining the features of the invention in an exemplary embodiment of the invention. The method flowchart 500 describes a method for positioning a slider 116 of a reversing valve 102 in heat pump/s. The method flowchart 500 starts at step 502.


At step 504, a control board 132 of system 200 or system 300 may receive a command from a thermostat 130 for operating a reversing valve 102 in a first mode, a second mode or a third mode. The reversing valve 102 may have a first surface 104 and a second surface 108. Further, the reversing valve 102 may comprise a first tube 106, a second, tube 110, and a third tube 112, and a fourth tube 114.


At step 506, the control board 132 of the system 200 or the system 300 may determine a tonnage profile for refrigerant to flow in the reversing valve 102 as discussed in FIG. 2 and FIG. 3 above. Further, the refrigerant may flow in a first flow in the first mode as explained in FIG. 2 above or in a second flow in the second mode or in the third mode as explained in FIG. 3 above.


At step 508, the control board 132 of the system 200 or the system 300 may communicate the command and the tonnage profile for refrigerant to a stepper motor 118.


At step 510, the stepper motor 118 of the system 200 or the system 300 may linearly move a lead screw 120 by the stepper motor 118 based on the command and the tonnage profile to position a slider 116. In specific, the slider 116 may be positioned on the second tube 110 and the third tube 112 in the second mode or on the second tube and the third tube in the third mode as explained in FIG. 3 above or may be positioned on the third tube 112 and the fourth tube 114 in the first mode as explained in FIG. 2 above. Then, the method flowchart 500 may end at 512.


The present invention is applicable to various fields such as, but not limited to, hospitality industry, museums, libraries, colleges, universities, hospitals, offices and any such building that is well known in the art and where the heat pump/s having the reversing valve is used.


The order of execution or performance of the operations in examples of the invention illustrated and described herein is not essential, unless otherwise specified. That is, the operations may be performed in any order, unless otherwise specified, and examples of the invention may include additional or fewer operations than those disclosed herein. For example, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the invention.


When introducing elements of aspects of the invention or the examples thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The term “exemplary” is intended to mean “an example of” The phrase “one or more of the following: A, B, and C” means “at least one of A and/or at least one of B and/or at least one of C”.


Having described aspects of the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the invention as defined in the appended claims. As various changes could be made in the above constructions, products, and methods without departing from the scope of aspects of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.


Although the subject matter has been described in language specific to structural features and/or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims.

Claims
  • 1. A system comprising: a reversing valve adapted to operate in a first mode, a second mode or a third mode, the reversing valve comprises a first tube, a second tube, a third tube, and a fourth tube;a control board adapted to:receive a command for operating the reversing valve in the first mode, the second mode or the third mode;determine a tonnage profile for refrigerant to flow in the reversing valve, the refrigerant flows in a first flow in the first mode, in a second flow in the second mode or in the second flow in the third mode; andcommunicate the command and the tonnage profile for the refrigerant to a stepper motor; andthe stepper motor adapted to:linearly move a lead screw based on the command and the tonnage profile to position a slider on the second tube and the third tube in the second mode or on the third tube and the fourth tube in the first mode or on the second tube and the third tube in the third mode.
  • 2. The system of claim 1, wherein the tonnage profile for refrigerant is determined based on a temperature defined by a user.
  • 3. The system of claim 1, wherein the slider is variably positioned at a first position for a first tonnage profile, at a second position for a second tonnage profile and/or at a third position for a third tonnage profile.
  • 4. The system of claim 1, wherein the stepper motor is adapted to perform a first number of steps for positioning the slider at a first position, a second number of steps for positioning the slider at a second position and/or a third number of steps for positioning the slider at a third position.
  • 5. The system of claim 1, wherein the stepper motor is adapted to determine an incorrect position of the slider based on a current location of the slider, wherein the control board is adapted to verify the incorrect position of the slider with respect to a programmed location of the slider and is adapted to provide a command to the stepper motor to move the slider to a desired location.
  • 6. The system of claim 1, wherein the lead screw is linearly moved in an inward direction in the second mode or the third mode to position the slider on the second tube and the third tube.
  • 7. The system of claim 1, wherein the lead screw is linearly moved in an outward direction in the first mode to position the slider on the third tube and the fourth tube.
  • 8. The system of claim 1, wherein the first mode is a heating mode, the second mode is a cooling mode and the third mode is a defrost mode.
  • 9. The system of claim 1, wherein the first tube is a compressor discharge tube, wherein the first tube is positioned at a first surface of the reversing valve.
  • 10. The system of claim 1, wherein the second tube, the third tube, and the fourth tube are positioned at a second surface of the reversing valve.
  • 11. The system of claim 1, wherein the second tube acts as a condenser tube, the third tube acts as a compressor return tube, and the fourth tube acts as an evaporator tube in the first mode.
  • 12. The system of claim 1, wherein the second tube acts as an evaporator tube, the third tube acts as a compressor return tube, and the fourth tube acts as a condenser tube in the second mode and/or in the third mode.
  • 13. The system of claim 1, wherein the second tube is connected to an indoor unit and the fourth tube is connected to an outdoor unit in the first mode, in the second mode and/or in the third mode.
  • 14. The system of claim 1, wherein the refrigerant flows from a compressor to the first tube, from the first tube to the second tube and from the second tube to an indoor unit in the first flow.
  • 15. The system of claim 1, wherein the refrigerant flows from a compressor to the first tube, from the first tube to the fourth tube and from the fourth tube to an outdoor unit in the second flow.
  • 16. The system of claim 1, wherein the slider is a C-shaped slider or a U-shaped slider.
  • 17. A method comprising: receiving, by a control board, a command for operating a reversing valve in a first mode, a second mode or a third mode, the reversing valve comprises a first tube, a second tube, a third tube, and a fourth tube;determining, by the control board, a tonnage profile for refrigerant to flow in the reversing valve, the refrigerant flows in a first flow in the first mode, in a second flow in the second mode or in the second flow in the third mode;communicating the command and the tonnage profile for refrigerant to a stepper motor; andlinearly moving a lead screw by the stepper motor based on the command and the tonnage profile to position a slider on the second tube and the third tube in the second mode or on the third tube and the fourth tube in the first mode or on the second tube and the third tube in the third mode.
  • 18. The method of claim 17, wherein the slider is variably positioned at a first position for a first tonnage profile, at a second position for a second tonnage profile and/or at a third position for a third tonnage profile.
  • 19. The method of claim 17 wherein the lead screw is linearly moved in an inward direction in the second mode or in the third mode to position the slider on the second tube and the third tube and the lead screw is linearly moved in an outward direction in the first mode to position the slider on the third tube and the fourth tube.
  • 20. The method of claim 17, wherein the first mode is a heating mode, the second mode is a cooling mode and the third mode is a defrost mode.
Priority Claims (1)
Number Date Country Kind
201911048669 Nov 2019 IN national