Compressor

• US 5,857,348 A
• Filed: 03/08/1996
• Issued: 01/12/1999
• Est. Priority Date: 06/15/1993
• Status: Expired due to Term

• Current Assignee: Danfoss A/S
• Original Assignee: Multistack International Limited (Multistack)
• Inventors: Conry, Ronald David
• Primary Examiner(s): Wayner, William
• Application Number:
  US08/578,563
• Time in Patent Office: 1,040 Days
• Field of Search: 310/90.5, 417/423.14, 417/423.12, 62/217, 62/508, 62/228.5, 62/209, 62/505
• US Class Current: 62/209
• CPC Class Codes: F04D 25/06 the pump being electrically driven F04D25/08 takes precedence
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/057 hydrostatic; hydrodynamic
• CPC Class Codes: F04D 29/058 magnetic; electromagnetic
• CPC Class Codes: F04D 29/5806 Cooling the drive system
• CPC Class Codes: F05D 2230/21 by casting
• CPC Class Codes: F05D 2300/173 Aluminium alloys, e.g. AlCuMgPb
• CPC Class Codes: F05D 2300/43 Synthetic polymers, e.g. plastics; Rubber
• CPC Class Codes: F25B 1/053 of turbine type
• CPC Class Codes: F25B 1/10 with multi-stage compression with cascade operation F25B7/00
• CPC Class Codes: F25B 49/022 Compressor control arrangements
• CPC Class Codes: F25B 49/025 Motor control arrangements

Abstract

A centrifugal type refrigerant compressor comprises at least one impeller (17, 18), electric motor (27) and drive shaft (22) mounted on non-lubricated radial bearings, such as magnetic or foil gas bearings (23, 24), with axial locating means (26) associated with the shaft (22) to restrict axial movement thereof with respect to the compressor housing (12). The housing (12) encases the motor (27) and the compressor and defines the gas inlet (31) and the gas outlet (16) passageways. Gas throttling means (34) is provided in the inlet (31), and a control means (30) varies the speed of the motor (27) and the throttling means (34) to control the compression ratio and mass flow through the compressor in accordance with the refrigeration load.

Claims

1. A compressor for compressing a refrigerant having liquid and gaseous phases, comprising:

at least one centrifugal compressor stage having an impeller mounted on a shaft, the shaft being supported by oilless radial bearings;

an electric motor for driving the shaft, the motor including a rotor connected to the shaft;

axial locating means associated with the shaft to restrict axial movement thereof;

a housing enclosing the motor and said at least one impeller, said housing incorporating an axially extending gas inlet and a gas outlet passage;

gas throttling means in the inlet to control the supply of gas to the impeller, passageways in the housing to convey liquid refrigerant to cool the motor and to convey refrigerant gas from the motor to the gas inlet; and

control means to control the gas throttling means in response to a refrigeration load, said control means adapted to generate control signals based on said load, said throttling means responsive to said control signals.

2. A compressor according to claim 1 wherein a second centrifugal compressor stage receives gas from the first stage and includes a second impeller mounted on the shaft.

3. A compressor according to claim 1 wherein said motor is located between said first and second compressor stages and said housing incorporates a duct to convey gas from an outlet of said first stage to an axially disposed inlet of said second stage.

4. A compressor according to claim 3 wherein a gas port conveys refrigerant gas from a refrigerant expansion chamber to the second compressor stage.

5. A compressor according to claim 3 wherein a gas port conveys refrigerant gas from a refrigerant expansion chamber to the second compressor stage.

6. A compressor according to claim 5 wherein said expansion chamber is integral with the housing and includes a liquid refrigerant level sensor and valve to control the refrigerant flow into the chamber in accordance with load.

7. A compressor according to claim 2 wherein said motor is located between said first and second compressor stages and said housing incorporates a duct to convey gas from an outlet of said first stage to an axially disposed inlet of said second stage.

8. A compressor according to claim 1 wherein said axial locating means comprises an active axial magnetic thrust bearing.

9. A compressor according to claim 1 wherein said axial locating means comprises a pair of passive magnetic thrust bearings each having a first permanent magnet secured to respective ends of the shaft and a second permanent magnet secured to the housing adjacent the respective first magnets, the magnets of each pair having like poles adjacent to repel each other thereby centering the shaft between the said second magnets.

10. A compressor according to claim 1 wherein said axial locating means comprises axial foil gas bearings.

11. A compressor according to claim 1 wherein said oilless radial bearings comprise foil gas bearings.

12. A compressor according to claim 1 wherein said gas throttling means comprises a plurality of radially extending vanes in the gas inlet, each vane being rotatable between open and closed positions about a radial axis by a control ring within the housing in response to control signals from said control means.

13. A compressor according to claim 1 wherein said housing includes an inner housing formed by injection molding synthetic plastics material, the inner housing forming bearing supports, refrigerant passageways, motor stator support and gas labyrinths.

14. A compressor according to claim 13 wherein said housing includes an outer housing of die-cast aluminium alloy.

15. A refrigeration system comprising a compressor as claimed in claim 1, a refrigerant condenser to condense the refrigerant gas passing from the gas outlet passage, an expansion chamber, an expansion device and an evaporator means, and said control means receives input signals from the evaporator means, pressure transducers in the gas inlet and gas outlet passage, gas throttling means, motor power supply means and motor speed sensor means and adjusts the motor speed and gas throttling means in accordance with system load and logic control parameters to maintain predetermined refrigerant flow through the compressor.

16. A system according to claim 15 wherein said control logic is substantially as described with reference to FIGS. 6a, 6b and 6c.

17. A compressor according to claim 1 wherein said oilless radial bearings comprise active magnetic bearings having control circuitry to maintain a predetermined spacing between rotating and stationary bearing surfaces.

18. A compressor according to claim 1 wherein a second centrifugal compressor stage receives gas from the first stage and includes a second impeller mounted on the shaft.

19. A compressor according to claim 1 wherein said motor is located between said first and second compressor stages and said housing incorporates a duct to convey gas from an outlet of said first stage to an axially disposed inlet of said second stage.

20. A refrigeration compressor comprising:

at least one centrifugal compressor stage having an impeller mounted on a shaft;

an electric motor to drive the shaft, the motor including a rotor connected to the shaft and the shaft being supported by active magnetic bearings having control circuitry to maintain a predetermined spacing between rotating and stationary bearing surfaces;

axial locating means associated with the shaft to restrict axial movement thereof;

a housing enclosing the motor and impeller, said housing incorporating an axially extending gas inlet and a gas outlet passage;

passageways in the housing to convey refrigerant to cool the motor and to convey refrigerant gas from the motor to the gas inlet;

gas throttling means in the inlet to control the supply of gas to the impeller, said gas throttling means comprising a plurality of radially extending vanes in the gas inlet, each vane being rotatable between open and closed positions about a radial axis by a control ring within the housing in response to control signals from said control means; and

control means to control the gas throttling means in response to a refrigeration load.

21. The compressor according to claim 20 wherein said axial locating means comprises an active axial magnetic thrust bearing.

22. The compressor according to claim 20 wherein said axial locating means comprises a pair of passive magnetic thrust bearings each having a first permanent magnet secured to respective ends of the shaft and a second permanent magnet secured to the housing adjacent the respective first magnets, the magnets of each pair having like poles adjacent to repel each other, thereby centering the shaft between the said second magnets.

23. The compressor according to claim 20 wherein said housing includes an inner housing formed by injection molding synthetic plastics material, the inner housing forming bearing supports, said refrigerant passageways, a motor stator support and gas labyrinths.

24. The compressor according to claim 23 wherein said housing includes an outer housing of die-cast aluminum alloy.

25. A refrigeration system comprising:

a compressor having at least one centrifugal compressor stage with an impeller mounted on a shaft;

an electric motor to drive the shaft, the motor including a rotor connected to the shaft and the shaft being supported by oilless radial bearings;

axial locating means associated with the shaft to restrict axial movement thereof;

a housing enclosing the motor and impeller, said housing incorporating an axially extending gas inlet and a gas outlet passage;

gas throttling means in the inlet to control the supply of gas to the impeller;

control means to control the gas throttling means in response to load;

a refrigerant condenser to condense the refrigerant gas passing from the gas outlet passage;

an expansion chamber;

an expansion device; and

an evaporator means,

wherein said control means receives input signals from the evaporator means, pressure transducers in the gas inlet and gas outlet passage, gas throttling means, motor power supply means and motor speed sensor means and operates to adjust the motor speed and gas throttling means in accordance with system load and logic control parameters to maintain predetermined refrigerant flow through the compressor.

26. The system according to claim 25 wherein said housing incorporates passageways to convey refrigerant to cool the motor and to convey refrigerant gas from the motor to the gas inlet.

27. The system according to claim 25 wherein a second centrifugal compressor stage receives gas from the first stage and includes a second impeller mounted on the shaft.

28. The compressor according to claim 25 wherein said motor is located between said first and second compressor stages and said housing incorporates a duct to convey gas from an outlet of said first stage to an axially disposed inlet of said second stage.

29. The compressor according to claim 27 wherein a gas port conveys refrigerant gas from a refrigerant expansion chamber to the second compressor stage.

30. The compressor according to claim 29 wherein said expansion chamber is integral with the housing and includes a liquid refrigerant level sensor and valve to control the refrigerant flow into the chamber in accordance with load.

31. The system according to claim 25 wherein said control logic uses input data from said input signals and from pre-programed memory and determines motor speed and gas throttling to maintain predetermined operating parameters.