Compressor protection and diagnostic system

• US 20050196285A1
• Filed: 12/30/2004
• Published: 09/08/2005
• Est. Priority Date: 12/30/2003
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Jayanth, Nagaraj
• Granted Patent: US 7,290,989 B2
• Time in Patent Office: Days
• US Class Current: 417/44.11
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04C 18/0215 where only one member is moving
• CPC Class Codes: F04C 2240/803 Electric connectors or cables; Fittings therefor
• CPC Class Codes: F04C 2270/80 Diagnostics
• CPC Class Codes: F04C 23/008 Hermetic pumps
• CPC Class Codes: F04C 28/28 Safety arrangements; Monitoring
• CPC Class Codes: H01R 13/6683 with built-in sensor
• CPC Class Codes: H02H 3/006 Calibration or setting of parameters
• CPC Class Codes: H02H 3/08 responsive to excess current responsive to abnormal temperature caused by excess current H02H5/04
• CPC Class Codes: H02H 3/085 making use of a thermal sensor, e.g. thermistor, heated by the excess current also responsive to the temperature of the protected device H02H5/041, thermal images H02H6/00
• CPC Class Codes: H02H 5/041 additionally responsive to excess current H02H5/048 takes precedence
• CPC Class Codes: H02H 7/08 for dynamo-electric motors
• CPC Class Codes: Y10S 417/902 Hermetically sealed motor pump unit

Abstract

A compressor assembly includes a shell, a compressor housed within the shell, and a motor drivingly connected to the compressor. In addition, a sensor assembly is provided for monitoring operating parameters of the compressor assembly. Processing circuitry, in communication with the sensor assembly, is operable to process the operating parameters of the compressor assembly according to predefined rules. Furthermore, a terminal assembly is hermetically secured to the shell and is in communication with the sensor assembly. A plug is attached to the terminal assembly outside of the shell and serves to operably connect the processing circuitry with the sensor assembly.

Claims

1. A compressor assembly comprising:

a shell;

a compressor housed within said shell;

a motor drivingly connected to said compressor;

a sensor assembly operable to monitor operating conditions of said compressor, said sensor assembly including at least one sensor sensing the temperature of an electrical conductor supplying current to said motor.

2. The compressor assembly of claim 1, wherein said at least one sensor is a negative temperature coefficient sensor.

3. The compressor assembly of claim 1, wherein said at least one sensor is disposed within said shell.

4. The compressor assembly of claim 1, wherein said at least one sensor is disposed external to said shell.

5. The compressor assembly of claim 1, wherein said sensor assembly includes a printed circuit board disposed within said shell and operably supporting said at least one sensor.

6. The compressor assembly of claim 5, wherein said printed circuit board supports said electrical conductor.

7. The compressor assembly of claim 1, wherein said electrical conductor includes a pin connected to said motor to supply said motor with current.

8. The compressor assembly of claim 7, wherein said pin is disposed within said shell.

9. The compressor assembly of claim 7, wherein said pin is disposed external to said shell.

10. The compressor assembly of claim 7, wherein said pin includes a measurement region disposed along said pin and said at least one sensor is disposed proximate to said measurement region.

11. The compressor assembly of claim 10, wherein said measurement region includes a smaller cross-sectional area than the remainder of said pin.

12. The compressor assembly of claim 1, further including processing circuitry operable to receive information from said at least one sensor to determine an operating condition of said compressor.

13. The compressor assembly of claim 12, wherein said processing circuitry further comprises a series of light emitting devices operable to selectively illuminate in response to sensed compressor parameters.

14. The compressor assembly of claim 12, wherein said processing circuitry includes a microprocessor.

15. The compressor assembly of claim 1, wherein said sensor assembly further includes a motor temperature sensor operable to monitor a temperature of said motor.

16. The compressor assembly of claim 1, wherein said sensor assembly further includes a compressor temperature sensor operable to monitor a temperature of said compressor.

17. The compressor assembly of claim 1, further comprising a hermetic feed-through assembly operable to connect said sensor assembly to said processing circuitry through said shell to maintain a hermetic seal of said compressor.

18. The compressor assembly of claim 1, wherein said electrical conductor is serially connected to said motor.

19. The compressor assembly of claim 18, wherein said electrical conductor is serially connected to windings of said motor.

20. The compressor assembly of claim 18, wherein said motor is drivingly connected to said compressor and said sensor assembly is operable to detect locked rotor conditions by monitoring the temperature of said electrical conductor.

21. A compressor assembly comprising:

a shell;

a compressor housed within said shell;

a motor drivingly connected to said compressor;

at least one current sensor operable to sense a current drawn by said motor;

at least one temperature sensor disposed within said shell; and

processing circuitry operable to receive data from said at least one current sensor and said at least one temperature sensor to determine operating conditions of said compressor.

22. The compressor assembly of claim 21, wherein said at least one temperature sensor is disposed proximate to a discharge port of said compressor and is operable to detect a discharge gas temperature.

23. The compressor assembly of claim 21, wherein said at least one temperature sensor is disposed proximate to a discharge port of said compressor and is operable to detect a material temperature near said discharge port.

24. The compressor assembly of claim 21, wherein said at least one temperature sensor is a negative temperature coefficient sensor.

25. The compressor assembly of claim 21, further comprising a printed circuit board disposed within said shell.

26. The compressor assembly of claim 25, wherein said printed circuit board operably supports said at least one temperature sensor.

27. The compressor assembly of claim 21, wherein said current sensor is disposed within said shell.

28. The compressor assembly of claim 21, wherein said current sensor is disposed external from said shell.

29. The compressor assembly of claim 21, wherein said at least one temperature sensor includes a motor temperature sensor operable to monitor a temperature of said motor.

30. The compressor assembly of claim 21, wherein said at least one temperature sensor includes a compressor temperature sensor operable to monitor a temperature of said compressor.

31. The compressor assembly of claim 21, further comprising a hermetic feed-through assembly operable to connect said at least one temperature sensor to said processing circuitry through said shell to maintain a hermetic seal of said compressor.

32. The compressor assembly of claim 21, wherein said processing circuitry further comprises a series of light emitting devices operable to selectively illuminate in response to sensed compressor parameters.

33. The compressor assembly of claim 21, wherein said processing circuitry includes a microprocessor.