Compressor protection and diagnostic system

• US 7,290,989 B2
• Filed: 12/30/2004
• Issued: 11/06/2007
• 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
• Primary Examiner(s): Stashick; Anthony
• Assistant Examiner(s): Dwivedi; Vikansha
• Application Number:
  US11/027,757
• Publication Number:
  US 20050196285A1
• Time in Patent Office: 1,041 Days
• Field of Search: 417/12, 417/18, 417/32, 417/63, 417/44.1, 310/68.B, 310/68.C, 310/68.R, 310/71, 318/432, 318/471, 318/472, 318/473, 388/934
• US Class Current: 417/44.1
• 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;

an electrical conductor that supplies current to said motor;

a temperature sensor disposed within and detecting a temperature of a measurement region of said electrical conductor; and

a controller in communication with said temperature sensor and operable to estimate a current drawn by said motor based on said sensed temperature.

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

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

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

5. The compressor assembly of claim 1, further comprising a printed circuit board disposed within said shell that supports said temperature 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 measurement region is disposed along said pin.

11. The compressor assembly of claim 7, wherein said measurement region includes a smaller cross-sectional area of said pin.

12. The compressor assembly of claim 1, wherein said controller determines an operating condition of said compressor based on said estimated current draw.

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

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

15. The compressor assembly of claim 1, further comprising a motor temperature sensor in communication with said controller.

16. The compressor assembly of claim 1, further comprising a compressor temperature sensor that monitors a temperature of a component of said compressor, said compressor temperature sensor in communication with said controller.

17. The compressor assembly of claim 16, wherein said component of said compressor is at least one of an orbiting scroll member and a non-orbiting scroll member.

18. The compressor assembly of claim 1, further comprising a hermetic feed-through assembly that connects said temperature sensor to said controller through said shell to maintain a hermetic seal of said compressor.

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

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

21. The compressor assembly of claim 19, wherein said controller determines a locked rotor condition based on said estimated current draw.

31. The compressor assembly of claim 7, wherein said localized spot of increased electrical resistance is disposed along said pin.

22. A compressor assembly comprising:

a shell;

a compressor housed within said shell;

a motor drivingly connected to said compressor;

an electrical conductor that supplies current to said motor and including a localized spot of increased electrical resistance;

a temperature sensor detecting a temperature of said electrical conductor at said localized spot of increased electrical resistance.

23. The compressor assembly of claim 22, wherein said temperature sensor is a negative temperature coefficient sensor.

24. The compressor assembly of claim 22, wherein said temperature sensor is disposed within said shell.

25. The compressor assembly of claim 22, wherein said temperature sensor is disposed external to said shell.

26. The compressor assembly of claim 22, further comprising a printed circuit board disposed within said shell that supports said temperature sensor.

27. The compressor assembly of claim 26, wherein said printed circuit board supports said electrical conductor.

28. The compressor assembly of claim 22, wherein said electrical conductor includes a pin connected to said motor to supply said motor with current.

29. The compressor assembly of claim 28, wherein said pin is disposed within said shell.

30. The compressor assembly of claim 28, wherein said pin is disposed external to said shell.

32. The compressor assembly of claim 28, wherein said localized spot of increased electrical resistance includes a smaller cross-sectional area of said pin.

33. The compressor assembly of claim 22, further comprising a controller that determines an operating condition of said compressor based on data received from said temperature sensor.

34. The compressor assembly of claim 33, wherein controller estimates a current drawn by said motor and uses said estimated current draw to determine said operating condition.

35. The compressor assembly of claim 22, wherein said electrical conductor is serially connected to said motor.

36. The compressor assembly of claim 35, wherein said electrical conductor is serially connected to windings of said motor.

37. A compressor diagnostic device comprising:

a temperature sensor disposed within and detecting a temperature of a measurement region of an electrical conductor that supplies current to a motor of a compressor; and

a controller in communication with said temperature sensor and operable to estimate a current drawn by said motor based on said sensed temperature.

38. The compressor diagnostic device of claim 37, wherein said temperature sensor is a negative temperature coefficient sensor.

39. The compressor diagnostic device of claim 37, wherein said temperature sensor is disposed within a shell of said compressor.

40. The compressor diagnostic device of claim 37, wherein said temperature sensor is disposed external to a shell of said compressor.

41. The compressor diagnostic device of claim 37, further comprising a printed circuit board disposed within a shell of said compressor that supports said temperature sensor.

42. The compressor diagnostic device of claim 41, wherein said printed circuit board supports said electrical conductor.

43. The compressor diagnostic device of claim 37, wherein said electrical conductor includes a pin connected to said motor of said compressor to supply said motor with current.

44. The compressor diagnostic device of claim 43, wherein said pin is disposed within a shell of said compressor.

45. The compressor diagnostic device of claim 43, wherein said pin is disposed external to a shell of said compressor.

46. The compressor diagnostic device of claim 43, wherein said measurement region is disposed along said pin.

47. The compressor diagnostic device of claim 43, wherein said measurement region includes a smaller cross-sectional area of said pin.

48. The compressor diagnostic device of claim 37, wherein said controller determines an operating condition of said compressor based on said estimated current draw.

49. The compressor diagnostic device of claim 37, further comprising a motor temperature sensor in communication with said controller.

50. The compressor diagnostic device of claim 37, further comprising a compressor temperature sensor that monitors a temperature of a component of said compressor, said compressor temperature sensor in communication with said controller.

51. The compressor diagnostic device of claim 50, wherein said component of said compressor is at least one of an orbiting scroll member and a non-orbiting scroll member.

52. The compressor diagnostic device of claim 37, further comprising a hermetic feed-through assembly that connects said temperature sensor to said controller through a shell of said compressor to maintain a hermetic seal of said compressor.

53. The compressor diagnostic device of claim 37, wherein said electrical conductor is serially connected to said motor.

54. The compressor diagnostic device of claim 53, wherein said electrical conductor is serially connected to windings of said motor.

55. The compressor diagnostic device of claim 53, wherein said controller determines a locked rotor condition based on said estimated current draw.