The invention relates to a variable displacement compressor having a suction shutoff valve (SSV) that impedes noise generated by the compressor from reaching the evaporator, and a method of controlling a compressor having a SSV. More particularly, the SSV provides a variable restriction that increases the restriction in response to increasing discharge pressure if the discharge pressure is less than a threshold, and decreases the restriction if the discharge pressure is greater than the threshold.
Automobiles have air conditioners for reducing the temperature of air in an automobile passenger compartment. The air conditioner operates by compressing refrigerant using a compressor, reducing the temperature of the compressed refrigerant, and then expanding (uncompressing) the refrigerant to reduce the refrigerant temperature. The expanded refrigerant then flows through an evaporator used to lower the temperature of the air in the passenger compartment. Variable displacement compressors adjust a compressor's displacement to varying a compressor's refrigerant discharge flow and thereby reduce energy consumption by the compressor during certain operating conditions. Under low refrigerant flow conditions, a suction valve in the compressor can flutter and thereby create pressure pulsations that propagate into the air conditioner evaporator. These pressure pulsations may be heard inside the vehicle passenger compartment.
Some variable displacement compressors have a suction shutoff valve (SSV) to restrict or prevent suction flutter noise, sometime known as suction reed valve noise, from communication from the suction valve to the evaporator. However, a SSV providing adequate restriction at low flow conditions has undesirable flow restriction and pressure loss at high flow rates. At high flow rates it is advantageous to minimize the restriction of refrigerant flow to maximize compressor efficiency. What is needed is a SSV that has adequate restriction to prevent noise propagation out of the compressor at low refrigerant flow rates and reduced restriction at high refrigerant flow rates so that compressor efficiency is increased.
The subject invention provides a variable displacement air conditioning compressor having a suction valve capable of generating noise during low refrigerant flow conditions, and a suction shutoff valve (SSV) configured to provide a variable restriction sufficient to prevent the noise from propagating out of the compressor to an evaporator. The compressor also has a regulator valve in fluid communication with a discharge region containing refrigerant at a discharge pressure, wherein the regulator valve cooperates with the SSV to increase the variable restriction if the discharge pressure is indicative of a low refrigerant flow rate, and decrease the variable restriction if the discharge pressure is not indicative of a low refrigerant flow rate.
The regulator valve variably restricts fluid communication between the discharge region and an internal suction region for controlling or regulating the pressure of refrigerant in a regulated region to a regulated pressure, whereby the regulated pressure influences the variable restriction of the SSV. Discharge pressure is normally the highest pressure refrigerant in an operating air conditioner. By utilizing refrigerant from the discharge region during low flow, the restriction of the SSV can readily provide sufficient restriction to prevent noise propagation. However, at high refrigerant flow rates the influence of the discharge pressure would cause undesirable restriction. The subject invention overcomes this problem by blocking fluid communication between the regulated region and the discharge region if the discharge pressure or the discharge pressure minus the internal suction pressure is above a threshold. When the regulator valve blocks fluid communication with the discharge pressure, the regulated pressure is substantially equal to the internal suction pressure, and the restriction of the SSV is reduced.
The regulator valve has a valve body, a valve member, and a regulator spring, configured to allow refrigerant to pass from the discharge region to the regulated region for increasing the regulated pressure if the discharge pressure is less than a first threshold, thereby increasing the restriction of the SSV at low refrigerant flow rates, and prevent refrigerant passing from the discharge region for decreasing the regulated pressure if the discharge pressure is greater than the first threshold, thereby reducing the restriction of the SSV at high refrigerant flow rates.
The subject invention also provides a method of preventing noise generated at a low refrigerant flow rate by a suction valve from propagating out of the compressor, and reducing the restriction of the SSV at high refrigerant flow rates. The method includes the steps of increasing the variable restriction in response to the discharge pressure indicating low flow such that the noise is prevented from propagating out of the compressor, and decreasing the variable restriction in response to the discharge pressure not indicating low flow such that the efficiency of the compressor is increased at high flow rates.
Further features and advantages of the invention will appear more clearly on a reading of the following detail description of the preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings.
This invention will be further described with reference to the accompanying drawings in which:
In accordance with a preferred embodiment of this invention,
The compressor 10 may be an external-control type that requires an external signal to adjust the variable displacement, or the compressor 10 may be an internal-control, a pneumatic type that is self-adjusting, or a hybrid combination of the two types. The absolute value of the discharge pressure PD, the difference between the discharge pressure PD and some reference pressure, and the difference between the discharge pressure PD and the internal suction pressure PI (PD-PI) are all indicators of the status of a cooling system. Using PI as the reference pressure for determining PD-PI as the status indicator simplifies the hardware necessary to monitor the status. The low end of the range of possible values of PD-PI is indicative of either the cooling system just starting operation, in which case the refrigerant pressures throughout the air conditioning system are substantially equal, or indicative of the system being subject to a low operating load, such as could occur on a cooler or moderate temperature day. The high end of the range of possible values of PD-PI indicates that the operating load is relatively high, such as could occur on a hot day. If the operating load is low, then the refrigerant flow requirements are also low.
Referring now to
The piston 50 is configured to engage features of the first end portion 38 for creating a variable obstruction to refrigerant flowing through the opening 44, and thereby establishing a restriction on fluid communication and noise communication between the external suction region 20 and the internal suction region 28.
Referring again to
The piston 50 has a first face 56 defining a first face area 60 at one end of the piston, a second face 58 axially opposed to the first face 56 and defining a second face area 64, and a third face 67 having an annular shape concentric with and radially separated from, but adjacent to the second face area 64 and defining a third face area 68. An exemplary diameter of the first face 56 is 15 millimeters, so an exemplary first face area 60 is about 177 millimeters-squared. An exemplary diameter of the second face 58 is 8 millimeters, so an exemplary second face area 64 is about 50 millimeters-squared. The absolute size and relative sizes of each piston face areas 60, 64, and 68 are selected to provide desirable operating characteristics of the SSV 12 such as the desired variable restriction when various pressures are present. The arrangement of the piston 50 and the housing 30 cooperate to define a bleed cavity 76 containing refrigerant at a regulated pressure PB. Based on the exemplary face area values given above, an exemplary third face area 68 is about 127 (177-50) millimeters-squared.
The first face 56 is acted upon by refrigerant at the external suction pressure PE, the second face 58 is acted upon by refrigerant in the regulated pressure cavity 88 at the regulated pressure PR, and the third face is acted upon by refrigerant in a bleed cavity 76 at the bleed pressure PB. Refrigerant at the external suction pressure PE acting over the first face area 60 generates an opening force 62 (FO). Refrigerant at the regulated pressure PR acting over the second face area 64 and refrigerant at the bleed pressure PB acting over the third face area combine constructively to generate a closing force 66 (FC) in opposition to the opening force 62. A balance of forces including the opening force 62 and the closing force 66 influences the position of piston 50 within housing 30 for determining the degree of obstruction of opening 44.
The configuration of the piston 50 and the housing 30 is such that the value of the first face area 60 is approximately equal to the value of the second face area 64 combined with the value of the third face area 68. Alternative configurations for piston 50 and housing 30 include increasing the diameter of the second face 58 to equal the diameter of the first face 56, thereby eliminating the third face 67 and the bleed cavity 76. Alternative piston configurations include having two separate pieces defining the first face 56 and the second face 58 and the faces coupled by a spring (not shown). As illustrated in
The regulated pressure cavity 88 containing refrigerant at the regulated pressure PR is in fluidic communication with the internal suction region 28 through a restricted orifice 92. The regulated pressure cavity 88 is also in variably restricted fluidic communication with the discharge region 26 via the regulator valve 82. As can be seen in
The refrigerant in the regulated pressure cavity 88 has a regulated pressure PR. PR is determined by the variable restriction through the restricted orifice 92 and the regulator valve 82. For a given set of operating conditions, if the variable restriction of the restricted orifice 92 is substantially greater than the variable restriction of the regulator valve 82, then PR will be substantially equal to PD. Conversely, if the restriction of the restricted orifice 92 is substantially less than the degree of restricting of the regulator valve, then PR will be substantially equal to PI. It follows that the degree of restricting of the regulator valve can be controlled to regulate PR to any value between PD and PI. The spring rate and preload of the spring 90 and the sizes of the various orifice of the regulator valve 84 are tuned so that for a given compressor coupled to a given air conditioner in a given vehicle, the variable restriction of the SSV 12 is sufficient to prevent noise generated by the compressor from being heard in the passenger compartment.
In the embodiment shown, the SSV has a spring 80 arranged to bias the piston 50 in the closing direction. It is advantageous for the SSV 12 to be closed when the air conditioner is off or not active for discharging refrigerant to insure that the valve is closed when the compressor is re-activated. Furthermore, when the air conditioner is on and PR-PE differential is low, small perturbations in PR and PE can cause the piston 50 to generate audible noise. The spring 80 helps reduce the probability that piston 50 may generate noise. The spring rate of the spring 80 is selected as low as possible to minimize SSV restriction at high refrigerant flow rates, but large enough to overcome any piston to housing friction to assure that the SSV 12 is in the closed position when the air conditioner is not active. For the SSV 12 shown in
In the embodiment shown, the housing 30 includes a housing bleed orifice 74 providing fluid communication between the internal suction region 28 and the bleed cavity 76, and a piston bleed orifice 72 providing fluid communication between the bleed cavity 76 and the external suction region 20. The fluid communication provided by the housing bleed orifice 74 and the piston bleed orifice 72 helps to regulate the bleed pressure PB in bleed cavity to prevent excessive delay in the opening of the SSV 12 in the event that there is a sudden change in PE, PI, or PR. The optimum size of the housing bleed orifice 74 the piston bleed orifice 72 is dependent on the desired response characteristics of the SSV and is influenced by the volume of the bleed cavity 76. For the exemplary SSV 12 shown in
As shown in
Thus, a variable displacement compressor having a suction shutoff valve (SSV) effective to prevent noise from propagating to the evaporator at low flow rates and exhibit reduced restriction to refrigerant flow at high refrigerant flow rates is provided. The SSV has a closing force generated by the regulated pressure PR acting upon the second face area increases SSV restriction if the pressure difference PD-PI is less than a first threshold being indicative of low refrigerant flow, and decreases the restriction if the pressure difference is greater than the first threshold being indicative of high refrigerant flow.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.
This application claims the benefit of U.S. Provisional Application No. 61/132,287 filed Jun. 17, 2008.
Number | Name | Date | Kind |
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20080199328 | Hayashi et al. | Aug 2008 | A1 |
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0857874 | Aug 1998 | EP |
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Number | Date | Country | |
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20090311109 A1 | Dec 2009 | US |
Number | Date | Country | |
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61132287 | Jun 2008 | US |