Compressor sensor module
First Claim
1. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
- a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply;
a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and
a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects an unexpected variation of electric power from said power supply;
wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor,wherein said power supply includes first, second, and third phases, wherein said voltage signal generated by said first voltage sensor corresponds to said first phase, and wherein said current signal generated by said first current sensor corresponds to said first phase, said sensor module further comprising;
a third input connected to a second voltage sensor that generates a voltage signal corresponding to a voltage of said second phase; and
a fourth input connected to a third voltage sensor that generates a voltage signal corresponding to a voltage of said third phase;
wherein said processor is connected to said third and fourth inputs and detects said unexpected variation of electric power from said power supply based on voltage measurements received from said third and fourth inputs,wherein said unexpected variation of electric power includes a phase-loss condition, andwherein said processor compares voltage measurements received from said first, third, and fourth inputs and determines that said phase-loss condition exists when voltage measurements from said first input are less than a predetermined percentage of an average of voltage measurements from said third and fourth inputs.
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Accused Products
Abstract
A sensor module for a compressor having an electric motor connected to a power supply is provided. The sensor module includes: a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of the power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of the power supply; and a processor connected to the first and second inputs. The processor monitors the first and second inputs and, based on voltage measurements from the first input and current measurements from the second input, detects at least one of: (i) an unexpected variation of electric power from the power supply; and (ii) a mechanical malfunction. The processor is disposed within an electrical enclosure of the compressor, the electrical enclosure being configured to house electrical terminals for connecting the power supply to the electric motor.
1525 Citations
25 Claims
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1. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects an unexpected variation of electric power from said power supply; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said power supply includes first, second, and third phases, wherein said voltage signal generated by said first voltage sensor corresponds to said first phase, and wherein said current signal generated by said first current sensor corresponds to said first phase, said sensor module further comprising; a third input connected to a second voltage sensor that generates a voltage signal corresponding to a voltage of said second phase; and a fourth input connected to a third voltage sensor that generates a voltage signal corresponding to a voltage of said third phase; wherein said processor is connected to said third and fourth inputs and detects said unexpected variation of electric power from said power supply based on voltage measurements received from said third and fourth inputs, wherein said unexpected variation of electric power includes a phase-loss condition, and wherein said processor compares voltage measurements received from said first, third, and fourth inputs and determines that said phase-loss condition exists when voltage measurements from said first input are less than a predetermined percentage of an average of voltage measurements from said third and fourth inputs. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects an unexpected variation of electric power from said power supply; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said power supply includes first, second, and third phases, wherein said voltage signal generated by said first voltage sensor corresponds to said first phase, and wherein said current signal generated by said first current sensor corresponds to said first phase, said sensor module further comprising; a third input connected to a second voltage sensor that generates a voltage signal corresponding to a voltage of said second phase; and a fourth input connected to a third voltage sensor that generates a voltage signal corresponding to a voltage of said third phase, wherein said processor is connected to said third and fourth inputs and detects said unexpected variation of electric power from said power supply based on voltage measurements received from said third and fourth inputs, wherein said unexpected variation of electric power includes a voltage-imbalance condition, and wherein said processor calculates an average of voltage measurements received from said first, third, and fourth inputs and determines that said voltage-imbalance condition based on the greatest of;
a difference between voltage measurements from said first input and said average;
a difference between voltage measurements from said third input and said average; and
a difference between voltage measurements from said fourth input and said average.
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21. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects an unexpected variation of electric power from said power supply; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said power supply includes first, second, and third phases, wherein said voltage signal generated by said first voltage sensor corresponds to said first phase, and wherein said current signal generated by said first current sensor corresponds to said first phase, said sensor module further comprising; a third input connected to a second voltage sensor that generates a voltage signal corresponding to a voltage of said second phase; a fourth input connected to a third voltage sensor that generates a voltage signal corresponding to a voltage of said third phase; and a fifth input connected to a second current sensor that generates a current signal corresponding to a current of said second phase, wherein said processor is connected to said third, fourth, and fifth inputs and detects said unexpected variation of electric power from said power supply based on voltage measurements received from said third and fourth inputs and current measurements received from said fifth input, wherein said unexpected variation of electric power includes a current-delay condition, and wherein said processor determines that said current-delay condition exists when a current measurement from said second input is greater than a predetermined current threshold and a current measurement from said fifth input is not greater than said predetermined current threshold within a predetermined time period.
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22. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects a mechanical malfunction; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said mechanical malfunction includes a welded-contactor condition, and wherein said processor receives run-state data corresponding to a current run-state of said compressor, compares said voltage measurements from said first input with a voltage threshold, and determines that said welded-contactor condition exists based on said current run-state and said comparison.
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23. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects a mechanical malfunction; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said mechanical malfunction includes a locked-rotor condition, and wherein said processor compares said current measurements from said second input with a current threshold and determines that said locked-rotor condition exists when said current measurements are greater than said current threshold.
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24. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects a mechanical malfunction; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said mechanical malfunction includes a locked-rotor condition, and wherein said processor generates a buffer of said current measurements from said second input, determines a greatest current value from said buffer, compares said current measurements with said greatest current value from said buffer, and determines that said locked-rotor condition exists when said current measurements are greater than a predetermined percentage of said greatest current value.
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25. A sensor module for a compressor having an electric motor connected to a power supply, the sensor module comprising:
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a first input connected to a first voltage sensor that generates a voltage signal corresponding to a voltage of said power supply; a second input connected to a first current sensor that generates a current signal corresponding to a current of said power supply; and a processor connected to said first and second inputs that monitors said first and second inputs and that, based on voltage measurements from said first input and current measurements from said second input, detects a mechanical malfunction; wherein said processor is disposed within an electrical enclosure of said compressor, said electrical enclosure being configured to house electrical terminals for connecting said power supply to said electric motor, wherein said mechanical malfunction includes a protection-trip condition, and wherein said processor compares said voltage measurements with a voltage threshold and said current measurements with a current threshold and determines that said protection-trip condition exists when said voltage measurements are greater than said voltage threshold and said current measurements are less than said current threshold.
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Specification