Microprocessor-based control system for heat pump having distributed architecture

• US 5,475,986 A
• Filed: 02/01/1994
• Issued: 12/19/1995
• Est. Priority Date: 08/12/1992
• Status: Expired due to Term

• Current Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Original Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Inventors: Bahel, Vijay, Pham, Hung, Hickey, Mickey, Millet, Hank, Herroon, Gregory P.
• Primary Examiner(s): Tanner, Harry B.
• Application Number:
  US08/189,894
• Time in Patent Office: 686 Days
• Field of Search: 62/223, 62/211, 62/126, 62/127, 62/129, 62/130, 62/229, 62/228.1, 236/51, 236/94, 165/11.1, 165/12, 165/22
• US Class Current: 62/160
• CPC Class Codes: F24F 1/00 Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station
• CPC Class Codes: F24F 1/0003 characterised by a split arrangement, wherein parts of the air-conditioning system, e.g. evaporator and condenser, are in separately located units
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/41 Defrosting; Preventing freezing
• CPC Class Codes: F24F 11/46 Improving electric energy efficiency or saving
• CPC Class Codes: F24F 11/523 for displaying temperature data
• CPC Class Codes: F24F 11/64 using pre-stored data
• CPC Class Codes: F24F 11/67 Switching between heating and cooling modes
• CPC Class Codes: F24F 11/74 for controlling air flow rate or air velocity
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 11/84 using valves
• CPC Class Codes: F24F 11/86 by controlling compressors within refrigeration or heat pump circuits
• CPC Class Codes: F24F 11/871 by controlling outdoor fans
• CPC Class Codes: F24F 2110/20 Humidity
• CPC Class Codes: F24F 2140/00 Control inputs relating to system states
• CPC Class Codes: F25B 41/34 with the valve member being actuated by electric means, e.g. by piezoelectric actuators
• CPC Class Codes: F25B 41/35 by rotary motors, e.g. by stepping motors
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

The control system employs multiple, distributed architechure, processors in the indoor unit, the outdoor unit and optionally the thermostat unit. The overall system control functions are distributed across the processors, which communicate with one another over a communications link, employing a messaging system which allows sensor values to be obtained locally and transmitted to the other processors. The processors communicate to automatically refresh or update information during times when it will not degrade performance of critical functions.

Claims

1. In a heat pump system of the type which recirculates refrigerant through a fluid circuit between an indoor unit and an outdoor unit including a compressor coupled in the fluid circuit, and an electrically controlled expansion valve for controlling flow of refrigerant, a control system comprising:

a communications link connecting said indoor unit and said outdoor unit;

first processor associated with said indoor unit and coupled to said communications link;

second processor associated with said outdoor unit and coupled to said communications link;

a first temperature sensor coupled to said second processor for obtaining a first temperature value indicative of the outdoor air temperature;

a second temperature sensor coupled to said second processor for obtaining a second temperature value indicative of the temperature of the refrigerant discharged from said compressor;

said second processor having storage means for storing said first and second temperature values and having messaging means interfaced with said communications link for transmitting said first and second temperature values to said first processor means;

said first processor having storage means and having messaging means interfaced with said communications link and operative to interact with the messaging means of said second processor to receive and store said first and second temperature values;

said first processor being coupled to said expansion valve and being operable to control the setting of said expansion valve based on said first and second temperature values, thereby controlling the flow of refrigerant through the fluid circuit.

2. The control system of claim 1 wherein said heat pump system further includes a thermostat unit having third processor associated therewith;

said third processor being coupled to said communications link and having messaging means interfaced with said communications link;

said third processor having memory means and a display for providing visual numeric information;

said third processor means being operable to interact with the messaging means of at least one of said first and second processors to receive and store said first temperature value and to display said first temperature value.

3. The control system of claim 1 wherein said messaging means of said first and second processors comprises a request-reply mechanism whereby one of said first and second processors transmits a request message to the other and, in response to said request message, the other sends a reply message.

4. The control system of claim 1 wherein said messaging means comprises a predefined serial communications protocol .

5. The control system of claim 1 wherein said storage means of said first processor is nonvolatile memory.

6. The control system of claim 1 wherein said storage means of said second processor is nonvolatile memory.

7. The control system of claim 1 wherein said first and second processors implement an information storing system whereby information stored in the memory means of said processors is refreshed according to a predetermined priority.

8. The control system of claim 2 wherein said first, second and third processors implement an information storing system whereby information stored in the memory means of said processors is refreshed according to a predetermined priority.

9. The control system of claim 1 wherein said messaging means implements a predefined set of messages.

10. The control system of claim 9 wherein said predefined set of messages includes a first message type comprising data-less commands and a second message type comprising data-bearing messages.

11. The control system of claim 10 wherein said data-bearing messages comprise an identifying header followed by data and a check sum.

12. The control system of claim 9 wherein said predefined set of messages includes at least one flag data message for indicating the Boolean states of a plurality of variables.

13. The control system of claim 12 wherein said flag data message represents said Boolean states in bitwise fashion.

14. The control system of claim 1 wherein said outdoor unit includes a compressor coupled in said fluid circuit and wherein said second processor controls the operation of said compressor.

15. The control system of claim 14 wherein the messaging means of said second processor is interactive with the messaging means of said first processor to receive compressor control instructions from said first processor and wherein said second processor controls the operation of said compressor based on said compressor control instructions.

16. The control system of claim 1 wherein said heat pump system further includes a thermostat unit having third processor associated therewith;

a third temperature sensor coupled to said third processor for obtaining a third temperature value indicative of the indoor air temperature;

said third processor being coupled to said communications link and having messaging means interfaced with said communications link;

said third processor means being operable to interact with the messaging means of said first processors to transmit said third temperature value to said first processor and wherein said first processor uses said third temperature value as a setpoint value in controlling the flow of refrigerant through said fluid circuit.

17. The control system of claim 5 wherein said nonvolatile memory is preloaded with initial values, which values are thereafter updated and stored automatically during operation of the control system.

18. The control system of claim 6 wherein said nonvolatile memory is preloaded with initial values, which values are thereafter updated and stored automatically during operation of the control system.

19. The control system of claim 1 further comprising nonvolatile memory accessible by said first and second processors for storing system configuration information.

20. The control system of claim 1 further comprising nonvolatile memory accessible by said first and second processors for storing data resulting from self-adjusting parameters.

21. The control system of claim 1 further comprising nonvolatile memory accessible by said first and second processors for storing a record of system fault conditions.