Patent Grant
11280524
This application relates generally to heating, ventilation, air conditioning, and refrigeration systems, and, more particularly, to an electrical enclosure for components of a chiller system.
Chiller systems, or vapor compression systems, utilize a working fluid, typically referred to as a refrigerant that changes phases between vapor, liquid, and combinations thereof in response to being subjected to different temperatures and pressures associated with operation of the vapor compression system. In some chiller systems, multiple enclosures may be provided for multiple respective components (e.g., power sources, control systems, variable speed drives, etc.). In such chiller systems, the multiple enclosures may utilize separate cooling systems and complex wiring/couplings to properly serve their function within the chiller system. Indeed, the chiller systems may have an enlarged footprint to accommodate the multiple enclosures.
In an embodiment of the present disclosure, a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system includes a refrigerant loop and a compressor disposed along the refrigerant loop. The compressor is configured to circulate refrigerant through the refrigerant loop. The HVAC&R system also includes a control panel and a variable speed drive (VSD) enclosure communicatively coupled to the control panel. The VSD enclosure includes a main drive line variable speed drive (VSD) configured to receive input from the control panel and to supply power to a motor of the compressor, and an oil pump variable speed drive (VSD) configured to supply power to an oil pump. The oil pump is configured to supply lubricant to the compressor.
In another embodiment of the present disclosure, a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system includes a refrigerant loop and a compressor disposed along the refrigerant loop. The compressor is configured to circulate refrigerant through the refrigerant loop. The HVAC&R system also includes a control panel and a variable speed drive (VSD) enclosure communicatively coupled to the control panel. The VSD enclosure includes a main drive line variable speed drive (VSD) configured to receive input from the control panel and to supply power to a motor of the compressor, and a magnetic bearing controller configured to control magnetic bearings of the compressor.
In another embodiment of the present disclosure, a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system includes a variable speed drive (VSD) enclosure. The VSD enclosure includes a main drive line variable speed drive (VSD) configured to supply power to a motor and an oil pump variable speed drive (VSD) configured to supply power to a pump. The pump is configured to supply oil to one or more moving parts of the HVAC&R system. The VSD enclosure also includes a magnetic bearing controller configured to control magnetic bearings of the HVAC&R system.
Embodiments of the present disclosure include a system that may reduce production and performance costs of a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system. In certain HVAC&R systems, a chiller shell, or housing, may include multiple electrical enclosures for multiple sub-systems, or components, of the HVAC&R system. Particularly, an HVAC&R system may include an electrical enclosure for a chiller control panel, an electrical enclosure for a main drive line variable speed drive (VSD) panel, an electrical enclosure for an oil pump VSD, an electrical enclosure for a magnetic bearing controller (MBC) and/or an MBC power supply panel, and other enclosures. In some instances, each of the electrical enclosures for the sub-systems may require separate cooling systems. Further, the plethora of electrical enclosures for the different sub-systems may be mounted to a shell of the chiller, thereby requiring a large footprint of the chiller shell for mounting purposes. The separate cooling systems and power sources of the sub-systems may also draw an excessive amount of power to operate. Accordingly, the presently-disclosed embodiments may utilize a single electrical enclosure to house several sub-systems, such as electrical panels, with a unified cooling system. Indeed, the presently-disclosed embodiments may reduce a footprint of the sub-system electrical enclosures, reduce power drawn to cool the electrical enclosures, and reduce production and operation costs of the HVAC&R system.
Turning now to the drawings,
Some examples of fluids that may be used as refrigerants in the vapor compression system 14 are hydrofluorocarbon (HFC) based refrigerants, for example, R-410A, R-407, R-134a, hydrofluoro-olefin (HFO), “natural” refrigerants like ammonia (NH3), R-717, carbon dioxide (CO2), R-744, or hydrocarbon based refrigerants, water vapor, or any other suitable refrigerant. In some embodiments, the vapor compression system 14 may be configured to efficiently utilize refrigerants having a normal boiling point of about 19 degrees Celsius (66 degrees Fahrenheit or less) at one atmosphere of pressure, also referred to as low pressure refrigerants, versus a medium pressure refrigerant, such as R-134a. As used herein, “normal boiling point” may refer to a boiling point temperature measured at one atmosphere of pressure.
In some embodiments, the vapor compression system 14 may use one or more of a variable speed drive (VSDs) 52, a motor 50, the compressor 32, the condenser 34, the expansion valve or device 36, and/or the evaporator 38. The motor 50 may drive the compressor 32 and may be powered by a main drive line variable speed drive (VSD) 52. The main drive line VSD 52 receives alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides power having a variable voltage and frequency to the motor 50. In some embodiments, the main drive line VSD 52 may be housed within a VSD enclosure 53 (e.g., an electrical enclosure). As discussed below, the VSD enclosure 53 may house a variety of components. In some embodiments, the motor 50 may be powered directly from an AC or direct current (DC) power source. The motor 50 may include any type of electric motor that can be powered by a VSD or directly from an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.
The compressor 32 compresses a refrigerant vapor and delivers the vapor to the condenser 34 through a discharge passage. In some embodiments, the compressor 32 may be a centrifugal compressor. Further, in some embodiments, the discharge passage may include diffuser, such as variable geometry diffuser 33. The variable geometry diffuser 33 may modify its shape to adjust a fluid flow rate through the compressor 32. The refrigerant vapor delivered by the compressor 32 to the condenser 34 may transfer heat to a cooling fluid (e.g., water or air) in the condenser 34. The refrigerant vapor may condense to a refrigerant liquid in the condenser 34 as a result of thermal heat transfer with the cooling fluid. The refrigerant liquid from the condenser 34 may flow through the expansion device 36 to the evaporator 38. In the illustrated embodiment of
The refrigerant liquid delivered to the evaporator 38 may absorb heat from another cooling fluid, which may or may not be the same cooling fluid used in the condenser 34. The refrigerant liquid in the evaporator 38 may undergo a phase change from the refrigerant liquid to a refrigerant vapor. As shown in the illustrated embodiment of
As discussed in detail below, the VSD enclosure 53 may include a variety of electrical components, or panels, configured to perform a variety of functions of the vapor compression system 14. For example, the VSD enclosure 53 may include a cooling system, which may regulate a temperature within the VSD enclosure 53. Indeed, power sources, controllers, and the like within the VSD enclosure 53 may require a suitable temperature to operate efficiently and perform their intended functions.
Keeping this in mind,
The oil pump VSD 74 may receive alternating current (AC) power having a particular fixed line voltage and fixed line frequency from an AC power source, and may provide power having a variable voltage and frequency to an oil pump 78. In turn, the oil pump 78 may provide a lubricant, such as oil, to bearings and/or other moving parts of the compressor 32. Further, the oil pump 78 may be any suitable pump such as a twin gear pump, a rotor pump, or a front cover oil pump.
The VGD system 76, and more specifically, the VGD controller of the VGD system 76, may monitor the position of a variable geometry diffuser of the compressor 32 via one or more sensors and may actuate the diffuser between a fully open and a fully closed position in response to operating conditions of the compressor 32. For example, in some embodiments, the compressor 32 may operate by passing fluid over one or more compression mechanism such as pistons, rotors, scrolls, lobes, impellers and the like, depending on the type of compressor 32. The compression mechanism works on the fluid to increase a pressure of the fluid. However, the operation of the compression mechanism may create an adverse pressure gradient in the fluid flow. Indeed, regardless of the type of compression system of the compressor 32, the VGD system 76 may actuate the VGD 33 to stabilize fluid flow of the compressor 32.
The battery 72 may be any suitable battery capable of supplying power to the oil pump VSD 74, the main drive line VSD 52, the VGD system 76, the control panel 40, or any combination thereof. Indeed, the battery 72 may be a primary battery type, a secondary battery type, or any other suitable battery type.
In some embodiments, the power supply 71 may utilize any suitable power source such as a power grid, a battery, a solar panel, an electrical generator, a gas engine, the vapor compression system 14, or any combination thereof. Particularly, the power supply 71 may supply power to the main drive line VSD 52, the oil pump VSD 74, the VGD system 76, or any combination thereof. Additionally, or in the alternative, the power supply 71 may provide power to, or charge, the battery 72 and/or the UPS 70.
The UPS 70 is an electric apparatus which may provide back-up power to a load when a main power source to the load discontinues a supply of power. Particularly, the UPS 70 may provide power to the load substantially instantaneously when the main power source discontinues the supply of power. In some embodiments, the UPS 70 may utilize, or supply, power that is stored in batteries, supercapacitors, flywheels, or any combination thereof. In some embodiments, the UPS 70 may supply power to the oil pump VSD 74 and/or the VGD system 76 if the power supply 73 and/or the battery 72 discontinues a supply of power to the oil pump VSD 74 and/or the VGD system 76.
Further, in some embodiments, the VSD enclosure 53, and more specifically, components within the VSD enclosure 53, may be communicatively coupled to the control panel 40. For example, in some embodiments, the control panel 40 may provide instructions via the interface board 48 and/or the microprocessor 44 to the main drive line VSD 52, the VGD system 76, and/or the oil pump VSD 74 to operate in an intended manner. Indeed, in some embodiments, the instructions provided from the control panel 40 may be based on operator input (e.g., via the interface board 48) and/or may be based on data collected from one or more sensors of the vapor compression system 14.
As mentioned above, components (e.g., the main drive line VSD 52, the UPS 70, the battery 72, the power supply 70, the oil pump VSD 74, and/or the VGD system 76) of the VSD enclosure 53 may release heat, or thermal energy, within the VSD enclosure 53. Accordingly, the VSD enclosure 53 may include a cooling system 80 to regulate an internal temperature of the VSD enclosure 53. The cooling system 80 may include a heat exchanger 82, which may be an air to water heat exchanger and utilize a liquid cooling system. For example, in some embodiments, the heat exchanger 82 may receive water from the condenser 34. Particularly, the heat exchanger 82 may receive water from an outlet of the condenser 34 and/or from an intermediate stage within the condenser 34. Additionally, or in the alternative, the heat exchanger 82 may receive water from the evaporator 38. Particularly, the heat exchanger 82 may receive water from an outlet of the evaporator 38 and/or from an intermediate state within the evaporator 38.
The water received from the condenser 34 and/or the evaporator 38 may be routed through tubing (e.g., piping, coils, etc.) of the heat exchanger 82. Further, the cooling system 80 may also include one or more fans 84, which may push or pull air (e.g., internal air, ambient air, surrounding air, etc.) over the tubing. In some embodiments, the one or more fans 84 may pull air from a source external to the VSD enclosure 53, such as through a vent. Additionally, or in the alternative, the one or more fans 84 may circulate and recycle, or re-condition, air within the VSD enclosure 53. Further, in some embodiments, the battery 72 and/or the power supply 71 may be utilized to power the one or more fans 84.
Further, the water received by the heat exchanger 82 from the condenser 34 and/or the evaporator 38 may be chilled water (e.g., water at a suitably low temperature). In this manner, the air that the one or more fans 84 pushes or pulls over the tubes may exchange heat with the water flowing through the tubes to increase a temperature of the water and decrease a temperature of the air. Particularly, the heat exchanger 82 may remove heat and/or moisture from the air that is being pushed or pulled over the tubes to produce conditioned air. That is, the cooling system 80 may condition the air such that the air that is supplied from the cooling system 80 to the components (e.g., the main drive line VSD 52, the UPS 70, the battery 72, the power supply 70, the oil pump VSD 74, and the VGD system 76) within the VSD enclosure 53 may be at a suitably low temperature, as discussed in further detail below.
Once the water has traveled through the tubes of the heat exchanger 82 and has exchanged heat with the air that is pulled or pushed across the tubes, the water may be routed to a suitable location within the circuit of the vapor compression system 14. For example, after exchanging heat with the air, the water may undergo a phase change, such as from a liquid to a vapor, an increase in temperature, and/or an increase and/or decrease in pressure. Accordingly, when exiting the heat exchanger 80, the water may be routed to a section of the circuit of the vapor compression system 14 which contains water that substantially matches the pressure and temperature of the water exiting the heat exchanger 82.
In some embodiments, the cooling system 80 may also include a control device 86, one type of which may be a thermostat, which may be used to designate the temperature of the conditioned air output from the cooling system 80. Specifically, the control device 86 may be used to control the flow of air through the heat exchanger 82 by controlling a speed of the one or more fans 84. In some embodiments, other devices may be included in the cooling system 80, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other control or monitoring systems, and even systems that are remote from the building 12. In some embodiments, the control device 86 may receive input regarding a set point temperature, such as from an operator. The control device 86 may also receive data indicative of a temperature within the VSD enclosure 53, such as from a temperature sensor. The control device 86 may analyze the data indicative of the temperature within the VSD enclosure 53 and compare the temperature within the VSD enclosure to the set point temperature. Based on the comparison, the control device 86 may then increase or decrease a speed of the one or more fans 84 to modify the internal temperature of the VSD enclosure 53 to substantially match the set point temperature. Additionally, some embodiments, the cooling system 80 may utilize a heat sink to help regulate the temperature of the VSD enclosure 53.
In some embodiments, the cooling system 80 may regulate the temperature of the VSD enclosure 53 such that the internal temperature of the VSD enclosure 53 remains below 50 degrees Celsius. In some embodiments, the cooling system 80 may regulate the temperature of the VSD enclosure 53 to ensure that the temperature remains below 40 degrees Celsius.
Further, in the current embodiment, the VSD enclosure 53 may be communicatively coupled to the control panel 40 via one or more wires 90 or other suitable medium to transfer signals and/or data. Indeed, one or more components (e.g., the main drive line VSD 52, the UPS 70, the battery 72, the power supply 71, the oil pump VSD 74, and/or the VGD system 76) of the VSD enclosure 53 may receive various inputs from the control panel 40. More specifically, an operator may provide various commands through the interface board 48 to control one or more of the components within the VSD enclosure 53.
For example, in some embodiments, the compressor 32 may utilize magnetic bearings to support one or more moving parts. Particularly, in some embodiments, the compressor 32 may utilize permanent magnets to carry a static load of the one or more moving parts and utilize active magnets when the one or more moving parts deviate from an optimum position. Accordingly, the MBC system 92, and more specifically, the MBC controller, may monitor the position of the one or more moving parts (e.g., a shaft) of the compressor 32 relative to the magnetic bearings of the compressor 32 and send one or more signals to control the active magnets such that the load substantially remains at the optimum position.
In some embodiments, the MBC system 92 may receive power from the battery 72, the UPS 70, the power supply 71, or any combination thereof. For example, in certain embodiments, the battery 72 and/or the power supply 71 may supply power to the MBC system 92 consistently, and the UPS 70 may supply power to the MBC system 92 as a back-up power source of power. Further, the cooling system 80 may function as described above to regulate the internal temperature of the VSD enclosure 53, and by extent, regulate the temperature of the components within the VSD enclosure 53, which includes the MBC system 92.
Further, in the illustrated embodiment, the VSD enclosure 53 is communicatively coupled to the control panel 40 via the one or more wires 90 or other suitable medium to transfer signals and/or data. Indeed, one or more components (e.g., the main drive line VSD 52, the UPS 70, the battery 72, the power supply 70, the MBC system 92, and/or the VGD system 76) of the VSD enclosure 53 may receive various inputs from the control panel 40. More specifically, an operator may provide various commands through the interface board 48 to control one or more of the components within the VSD enclosure 53.
Further, in some embodiments, within the VSD enclosure 53, the MBC system 92, the UPS 70, and the VGD system 76 may be associated with a first electrical panel, and the main drive line VSD 52 may be associated with a second electrical panel. In such embodiments, the battery 72 may be coupled to the first electrical panel, the second electrical panel, or both, and the power supply 71 may be coupled to the first electrical panel, the second electrical panel, or both.
The oil pump VSD 74 may function as described above with respect to
In some embodiments, the MBC system 92 and/or the oil pump VSD 74 may receive power from the battery 72, the UPS 70, the power supply 71, or any combination thereof. For example, in certain embodiments, the battery 72 and/or the power supply 71 may supply power to the MBC system 92 and/or the oil pump VSD 74 consistently and the UPS 70 may supply power to the MBC system 92 and/or the oil pump VSD 74 as a back-up power source. Further, the cooling system 80 may function as described above to regulate the internal temperature of the VSD enclosure 53, and by extent, regulate the temperature of the components within the VSD enclosure 53, which includes the MBC system 92 and the oil pump VSD 74.
Further, in the current embodiment, the VSD enclosure 53 may be communicatively coupled to the control panel 40 via the one or more wires 90 or other suitable medium to transfer signals and/or data. Indeed, one or more components (e.g., the main drive line VSD 52, the UPS 70, the battery 72, the power supply 70, the MBC system 92, the oil pump VSD 74 and/or the VGD system 76) of the VSD enclosure 53 may receive various inputs from the control panel 40. More specifically, an operator may provide various commands through the interface board 48 to control one or more of the components within the VSD enclosure 53.
In the current embodiment, within the VSD enclosure 53, the main drive line VSD 52 may be associated with a first electrical panel, the oil pump VSD 74 may be associated with a second electrical panel, and the MBC system 92, the UPS 70, and the VGD system 76 may be associated with a third electrical panel. In such embodiments, the battery 72 may be coupled to the first electrical panel, the second electrical panel, the electrical third panel, or any combination thereof, and the power supply 73 may be coupled to the first electrical panel, the second electrical panel, the third electrical panel, or any combination thereof.
Accordingly, the present disclosure is directed to providing systems of a chiller system including a variable speed drive (VSD) enclosure (e.g., electrical enclosure) having a variety of components and/or panels. For example, the VSD enclosure may include an oil pump VSD, a magnetic bearing controller and/or a magnetic bearing controller power supply, a variable geometry diffuser controller and/or variable geometry diffuser power supply, a battery, a power supply, an uninterruptible power supply, or any combination thereof. Indeed, these components may be included on a variety of electrical panels within the VSD enclosure. Further, the VSD enclosure may utilize a unitary cooling system, such as an air to water heat exchanger, to regulate the temperature within the VSD enclosure. Indeed, each of the components within the VSD enclosure may be cooled by the unitary cooling system, thereby saving in cooling costs relative to systems utilizing multiple cooling systems for the multiple components. Further, due to the consolidation of the components to within the VSD enclosure, the footprint utilized by the components may be also be reduced. Still further, the components within the VSD enclosure may utilize common power sources, thereby saving in production and/or power costs.
While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the invention, or those unrelated to enabling the claimed invention). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.
This application is a U.S. National Stage Application of PCT International Application No. PCT/US2018/055251, entitled “SYSTEMS FOR A CHILLER ELECTRICAL ENCLOSURE,” filed Oct. 10, 2018, which claims priority from and the benefit of U.S. Provisional Application Ser. No. 62/570,517, entitled “SYSTEMS FOR A CHILLER ELECTRICAL ENCLOSURE,” filed Oct. 10, 2017, which are hereby incorporated by reference in their entireties for all purposes.
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| WO2019/075088 | 4/18/2019 | WO | A |
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