Refrigeration system with superheating, sub-cooling and refrigerant charge level control

• US 10,527,332 B2
• Filed: 11/17/2017
• Issued: 01/07/2020
• Est. Priority Date: 01/13/2016
• Status: Active Grant

• Current Assignee: Bergstrom Incorporated
• Original Assignee: Bergstrom Incorporated
• Inventors: Connell, Brett S., Sullivan, Aaron D., Herrmann, Brett J., Zeigler, Terry
• Primary Examiner(s): Duke, Emmanuel E
• Application Number:
  US15/816,993
• Publication Number:
  US 20180073789A1
• Time in Patent Office: 781 Days
• CPC Class Codes: F25B 13/00 Compression machines, plants or systems, with reversible cycle defrosting cycles F25B47/02
• CPC Class Codes: F25B 2339/0441 containing a drier or a filter
• CPC Class Codes: F25B 2345/00 Details for charging or discharging refrigerants; Service stations therefor
• CPC Class Codes: F25B 2345/001 Charging refrigerant to a cycle
• CPC Class Codes: F25B 2345/003 Control issues for charging or collecting refrigerant to or from a cycle
• CPC Class Codes: F25B 2345/006 characterised by charging or discharging valves
• CPC Class Codes: F25B 2400/16 Receivers
• CPC Class Codes: F25B 2500/24 Low amount of refrigerant in the system
• CPC Class Codes: F25B 2600/05 Refrigerant levels
• CPC Class Codes: F25B 2700/04 Refrigerant level
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/195 of the condenser
• CPC Class Codes: F25B 2700/2108 of a receiver
• CPC Class Codes: F25B 2700/2111 of a heat storage receiver
• CPC Class Codes: F25B 2700/2113 of a suction accumulator
• CPC Class Codes: F25B 40/02 Subcoolers
• CPC Class Codes: F25B 40/06 Superheaters
• CPC Class Codes: F25B 43/003 Filters
• CPC Class Codes: F25B 43/006 Accumulators
• CPC Class Codes: F25B 45/00 Arrangements for charging or discharging refrigerant
• CPC Class Codes: F25B 49/02 : for compression type machines, plants or systems

Abstract

The various embodiments described herein include methods, devices, and systems for determining refrigerant charge level. In one aspect, a refrigeration system includes: (1) a compressor to compress a refrigerant; (2) a condenser disposed downstream of the compressor to condense the refrigerant; (3) an evaporator disposed downstream of the condenser to vaporize the refrigerant; (4) refrigerant lines fluidly connecting the compressor, the condenser and the evaporator in series to form a refrigerant circuit for circulating the refrigerant; (5) at least one sensor configured to measure temperature and pressure of the refrigerant in the refrigerant circuit; and (6) a controller communicatively coupled to the at least one sensor and configured to: (a) determine a sub-cooling level or super-heating level based on the temperature and/or pressure measured by the at least one sensor; and (b) facilitate operation of the refrigeration system based on the sub-cooling level or the super-heating level.

Claims

1. A refrigeration system, comprising:

a refrigerant reservoir;

a compressor to compress a refrigerant;

a condenser disposed downstream of the compressor to condense the refrigerant;

an evaporator disposed downstream of the condenser to vaporize the refrigerant;

refrigerant lines fluidly connecting the compressor, the condenser and the evaporator in series to form a refrigerant circuit for circulating the refrigerant;

at least one sensor configured to measure a temperature of the refrigerant and a pressure of the refrigerant in the refrigerant circuit; and

a controller communicatively coupled to the at least one sensor and configured to;

determine a sub-cooling level or super-heating level based on the temperature or the pressure measured by the at least one sensor;

determine a refrigerant charge level based at least in part on the sub-cooling level or the super-heating level;

determine whether the refrigerant charge level is below a predetermined refrigerant charge level; and

in accordance with a determination that the refrigerant charge level is below the predetermined refrigerant charge level, selectively inject additional refrigerant from the refrigerant reservoir to the refrigerant circuit, thereby raising the refrigerant charge level to at least the predetermined refrigerant charge level.

2. The system of claim 1, further comprising a receiver drier disposed between the condenser and the evaporator, the receiver drier configured to perform one or more of the following:

temporarily store the refrigerant; and

absorb moisture from the refrigerant; and

wherein the at least one sensor includes a first sensor installed at the receiver drier to measure temperature and pressure of the refrigerant after it has passed through the condenser.

3. The system of claim 2, wherein the controller is further configured to determine the sub-cooling level based on the temperature and pressure measured by the first sensor.

4. The system of claim 1, further comprising an accumulator disposed between the evaporator and the compressor, the accumulator configured to restrict liquid refrigerant from entering the compressor;

and

wherein the at least one sensor includes a first sensor installed at the accumulator to measure temperature and pressure of the refrigerant after it has passed through the evaporator.

5. The system of claim 4, wherein the controller is further configured to determine a super-heating level based on the temperature and pressure measured by the first sensor.

6. The system of claim 1, further comprising an electronic valve fluidly connected to the refrigerant reservoir;

and

wherein the electronic valve is configured to enable flow of the additional refrigerant from the refrigerant reservoir to the refrigerant circuit, wherein the flow is driven in-part by a pressure difference between the refrigerant reservoir and the refrigerant circuit, thereby maintaining the refrigerant charge level at least at the predetermined refrigerant charge level.

7. The system of claim 1, further comprising:

an electronic valve fluidly connected to the refrigerant circuit and the refrigerant reservoir; and

wherein the controller operates the electronic valve to be selectively opened or closed in accordance with the determined sub-cooling level or super-heating level, thereby enabling flow of the refrigerant from the refrigerant reservoir to the refrigerant circuit.

8. The system of claim 1, wherein the at least one sensor includes a first temperature sensor and a first pressure sensor.

9. The system of claim 1, wherein controller is further configured to determine at least one of the sub-cooling level or the super-heating level using a look-up table in accordance with the temperature and pressure measured by the at least one sensor.

10. The system of claim 1, wherein the controller is further configured to:

determine a plurality of refrigerant charge levels by determining, at each of a plurality of distinct times, a respective refrigerant charge level based at least in part on a respective sub-cooling or super-heating level; and

predict whether the refrigerant charge level will be below a predetermined refrigerant level during a subsequent time period based on the determined plurality of refrigerant charge levels.

11. The system of claim 10, wherein predicting whether the refrigerant charge level will be below the predetermined refrigerant level is based on one or more of the following:

a trend of the determined plurality of refrigerant charge levels over time, exterior temperature, interior temperature, and humidity.

12. The system of claim 10, wherein the controller is further configured to predict how long the refrigerant will last based on the determined plurality of refrigerant charge levels.

13. The system of claim 1, wherein the controller is further configured to perform one or more of the following:

calculate a compression ratio of the compressor;

determine whether a blockage has occurred in the refrigerant circuit based on the calculated compression ratio; and

determine a location of the blockage based on at least one of the determined sub-cooling level or the determined super-heating level.

14. The system of claim 13, wherein the controller is further configured to output a signal to request maintenance if it is determined that a blockage has occurred.

15. The system of claim 1, wherein the controller is electrically coupled to the compressor and further configured to:

count clutch cycles of the compressor; and

predict clutch life of the compressor based on at least one of the clutch cycles, a clutch temperature, or a current through the compressor.

16. The system of claim 1, wherein the controller is communicatively coupled to an electronic device and further configured to output information regarding at least one of the sub-cooling level or the super-heating level to the electronic device.

17. The system of claim 1, wherein the controller is communicatively coupled to an electronic device and further configured to output a warning signal in accordance with a determination that at least one of:

the determined sub-cooling level is outside of a predetermined sub-cooling range;

or

the determined super-heating level is outside of a predetermined super-heating range.

18. The system of claim 1, wherein the controller is communicatively coupled to an electronic device and configured to output a warning signal in accordance with a determination that at least one of:

the determined sub-cooling level is outside of a predetermined sub-cooling range for a first predetermined period of time;

or

the determined super-heating level is outside of a predetermined super-heating range for a second predetermined period of time.

19. The system of claim 1, wherein the refrigeration system is installed in a vehicle;

and

wherein the compressor is configured to be driven by an internal combustion engine of the vehicle.

20. The system of claim 1, wherein the compressor is an electrically driven compressor.

21. A method for controlling a refrigeration system, comprising:

measuring, at one or more sensors, temperature and pressure of refrigerant within a refrigerant circuit of the refrigeration system;

determining a refrigerant sub-cooling level or a refrigerant super-heating level based on the temperature and pressure of the refrigerant;

determining a refrigerant charge level based at least in part on the refrigerant sub-cooling level or the refrigerant super-heating level;

determining whether the refrigerant charge level is below a predetermined refrigerant charge level; and

in accordance with a determination that the refrigerant charge level is below the predetermined refrigerant charge level, selectively injecting additional refrigerant to the refrigerant circuit, thereby raising the refrigerant charge level to at least the predetermined refrigerant charge level.

22. The method of claim 21, wherein determining the refrigerant charge level includes calculating the refrigerant charge level based at least in part on the refrigerant sub-cooling level and the refrigerant super-heating level

wherein selectively injecting the additional refrigerant to the refrigerant circuit includes selectively controlling a refrigerant valve to enable flow of the refrigerant from a refrigerant reservoir to the refrigerant circuit.

23. The method of claim 21, further comprising determining a plurality of refrigerant charge levels by determining, at each of a plurality of distinct times, a respective refrigerant charge level based at least in part on a respective sub-cooling or super-heating level;

and

predicting whether the refrigerant charge level will be below the predetermined refrigerant level during a subsequent time period based on the determined plurality of refrigerant charge levels.

24. The method of claim 23, further comprising determining how long the refrigerant will last based on the determined plurality of refrigerant charge levels.

25. The method of claim 21, further comprising calculating a compression ratio of a compressor of the refrigeration system;

and

determining whether a blockage has occurred in the refrigerant circuit based on the calculated compression ratio; and

determining a location of the blockage based on at least one of the sub-cooling level or the super-heating level.

26. The method of claim 21, further comprising sending information regarding at least one of the sub-cooling level or the super-heating level to an electronic device.

27. The method of claim 21, further comprising sending an alert to an electronic device in accordance with a determination that at least one of:

the determined sub-cooling level is outside of a predetermined sub-cooling range for a first predetermined period of time;

or

the determined super-heating level is outside of a predetermined super-heating range for a second predetermined period of time.