Structural frame cooling manifold

• US 10,462,942 B2
• Filed: 05/10/2017
• Issued: 10/29/2019
• Est. Priority Date: 12/08/2014
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Borisov, Konstantin, Nielsen, Mark A., Martinelli, Jeffrey A., Stauffer, Brian L., Gladfelter, Seth K., Todd, Michael S., Jadric, Ivan, Schreiber, Jeb W., Beckley, Tim
• Primary Examiner(s): Haughton, Anthony M
• Assistant Examiner(s): Gafur, Razmeen
• Application Number:
  US15/592,018
• Publication Number:
  US 20170245402A1
• Time in Patent Office: 902 Days
• Field of Search: 361676-678, 36167946-67954, 361688-723, 165 801- 805, 16510433, 165185, 174 151- 153, 174 161- 163, 174547, 174548, 257712-722, 257E23088, 24453, 24458-459, 454184, 312236
• CPC Class Codes: F25B 31/006 Cooling of compressor or motor
• CPC Class Codes: H02M 5/40 with intermediate conversion into dc
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence
• CPC Class Codes: H05K 7/14322 wherein the control and power circuits of a power converter are arranged within the same casing
• CPC Class Codes: H05K 7/20327 Accessories for moving fluid, for connecting fluid conduits, for distributing fluid or for preventing leakage, e.g. pumps, tanks or manifolds
• CPC Class Codes: H05K 7/20354 Refrigerating circuit comprising a compressor
• CPC Class Codes: H05K 7/20381 Thermal management, e.g. evaporation control
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change
• CPC Class Codes: H05K 7/20936 Liquid coolant with phase change

Abstract

A variable speed drive includes a converter connected to an AC power source, a DC link connected to the converter, and an inverter connected to the DC link. The inverter converts DC voltage into an output AC power having a variable voltage and frequency. The inverter includes at least one power electronics module and associated control circuitry; a heat sink in thermal communication with the power electronics module and in fluid communication with a manifold. The manifold includes a tubular member having at least one vertical member portion and at least one horizontal member portion in fluid communication. A plurality of ports conduct cooling fluid into and out of the manifold. A bracket attaches the manifold to a structural frame. Brackets are provided for attachment of power electronics modules to the manifold.

Claims

1. A cooling system for a variable speed drive (VSD), comprising:

a manifold coupled to a frame of the VSD and a VSD component to provide structural support to the frame of the VSD and the VSD component;

a cooling member coupled to the manifold and in a heat exchange relationship with the VSD component;

a fluid passageway of the manifold configured to flow a cooling fluid through the manifold; and

a plurality of ports disposed along the manifold, wherein the plurality of ports is in fluid communication with the fluid passageway and the cooling member, such that the plurality of ports enable the cooling fluid to flow between the fluid passageway and the cooling member.

2. The system of claim 1, wherein the plurality of ports is in fluid communication with a cooling fluid source, such that the plurality of ports is configured to receive the cooling fluid from the cooling fluid source, direct the cooling fluid from the fluid passageway to the cooling member, and discharge the cooling fluid back to the cooling fluid source.

3. The system of claim 2, wherein the cooling fluid source is a heat exchanger configured to transfer thermal energy from the cooling fluid to a working fluid of the heat exchanger.

4. The system of claim 3, wherein the working fluid of the heat exchanger is a refrigerant of a heating, ventilating, and air conditioning (HVAC) system.

5. The system of claim 1, wherein the cooling member and the VSD component are in a sealed relationship with one another.

6. The system of claim 1, wherein the VSD component is a switch of an inverter of the VSD.

7. The system of claim 1, wherein the VSD component is a direct current (DC) link capacitor.

8. The system of claim 1, wherein the manifold comprises a first member coupled to a base of the frame of the VSD and a second member coupled to an end panel of the frame of the VSD, wherein the plurality of ports is disposed along the second member.

9. The system of claim 8, wherein the first member is oriented vertically with respect to the base of the frame of the VSD and the second member is oriented horizontally with respect to the base of the frame of the VSD.

10. The system of claim 1, wherein the manifold is fabricated from a non-corrosive material.

11. The cooling system of claim 10, wherein the non-corrosive material is stainless steel.

12. A heating, ventilating, and air conditioning (HVAC) system, comprising:

a refrigerant loop;

a compressor disposed along the refrigerant loop and configured to circulate a refrigerant through the refrigerant loop;

a motor configured to drive the compressor;

a variable speed drive (VSD) configured to supply power to the compressor, wherein the VSD comprises a frame and a plurality of components configured to supply alternating current (AC) power to the motor at a variable voltage and a variable frequency; and

a cooling system for the VSD, comprising;

a manifold coupled to the frame of the VSD and configured to provide structural support to the frame of the VSD and a component of the plurality of components of the VSD;

a cooling member coupled to the manifold and in a heat exchange relationship with the component;

a fluid passageway of the manifold configured to flow a cooling fluid through the manifold; and

a plurality of ports disposed along the manifold, wherein the plurality of ports is in fluid communication with the fluid passageway and the cooling member, such that the plurality of ports enable the cooling fluid to flow between the fluid passageway and the cooling member.

13. The HVAC system of claim 12, wherein the plurality of components of the VSD comprises:

a converter configured to couple to an AC power source providing an input AC voltage and to convert the input AC voltage to a direct current (DC) voltage;

a DC link converter coupled to the converter, wherein the DC link converter is configured to filter the DC voltage and to store power from the converter; and

an inverter coupled to the DC link and configured to convert the DC voltage from the DC link into the AC power supplied to the motor.

14. The HVAC system of claim 13, wherein the cooling member of the cooling system of the VSD is in the heat exchange relationship with a switch of the inverter.

15. The HVAC system of claim 14, wherein the cooling member and the switch are in a sealed relationship with one another.

16. The HVAC system of claim 13, wherein the cooling member of the cooling system of the VSD is in the heat exchange relationship with the DC link converter.

17. The HVAC system of claim 12, wherein the manifold is coated with a polymeric material, a ceramic material, or a combination thereof.

18. A method for cooling a component of a variable speed drive (VSD), comprising:

receiving a flow of cooling fluid from a cooling fluid source through a first port of a manifold, wherein the manifold is coupled to a frame of the VSD and the manifold is configured to provide structural support to the frame of the VSD and the component the VSD;

directing the flow of cooling fluid through a fluid passageway of the manifold toward a second port of the manifold;

directing the flow of cooling fluid from the second port to a cooling member, wherein the cooling member is in a heat exchange relationship with the component of the VSD, such that the cooling fluid absorbs thermal energy from the component of the VSD;

directing the flow of cooling fluid from the cooling member to a third port of the manifold;

discharging the flow of cooling fluid from the manifold back to the cooling fluid source.

19. The method of claim 18, comprising directing the flow of cooling fluid from the third port into the fluid passageway of the manifold, and wherein discharging the flow of cooling fluid from the manifold back to the cooling fluid source comprises discharging the flow of cooling fluid through a fourth port of the manifold to the cooling fluid source.

20. The method of claim 18, comprising exchanging heat from the cooling fluid to a working fluid of a heat exchanger of the cooling fluid source after discharging the cooling fluid from the manifold.