Compressor crankcase heating control systems and methods

• US 9,353,738 B2
• Filed: 08/18/2014
• Issued: 05/31/2016
• Est. Priority Date: 09/19/2013
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Ramayya, George J.
• Primary Examiner(s): FREAY, CHARLES GRANT
• Application Number:
  US14/461,796
• Publication Number:
  US 20150075205A1
• Time in Patent Office: 652 Days
• Field of Search: 184/6.22
• US Class Current: 1/1
• CPC Class Codes: F04B 35/04 the means being electric
• CPC Class Codes: F04B 39/02 Lubrication of machines or engines in general F01M
• CPC Class Codes: F04B 39/0207 with lubrication control systems
• CPC Class Codes: F04B 39/06 Cooling; Heating; Prevention of freezing
• CPC Class Codes: F04B 39/128 Crankcases
• 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 2240/30 Casings or housings
• CPC Class Codes: F04C 29/005 Means for transmitting movement from the prime mover to driven parts of the pump, e.g. clutches, couplings, transmissions
• CPC Class Codes: F04C 29/0085 Prime movers
• CPC Class Codes: F04C 29/04 Heating; Cooling of machines or engines in general F01P; Heat insulation heat insulation in general F16L59/00
• CPC Class Codes: F25B 13/00 Compression machines, plants or systems, with reversible cycle defrosting cycles F25B47/02
• CPC Class Codes: F25B 2400/01 Heaters
• CPC Class Codes: F25B 2600/02 Compressor control
• CPC Class Codes: F25B 2600/021 Inverters therefor
• CPC Class Codes: F25B 2600/111 of condenser fans
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21152 at the discharge side of the compressor
• CPC Class Codes: F25B 31/002 Lubrication
• CPC Class Codes: F25B 31/023 with compressor of reciprocating-piston type
• CPC Class Codes: F25B 31/026 : with compressor of rotary type
• CPC Class Codes: F25B 49/025 : Motor control arrangements
• CPC Class Codes: Y02B 30/70 : Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A first switching device includes a first and second inputs connected to first and second power lines, respectively, the first and second power lines for receiving a first voltage. The first switching device selectively connects and disconnects the first and second inputs to and from first and second nodes, respectively. A second switching device includes a third input connected to the first node, includes a fourth input connected to a third power line, and includes a first output connected to a first end of a stator winding. A third switching device includes a fifth input connected to the second node and includes a sixth input connected to a fourth power line, the third and fourth power lines for receiving a second voltage that is less than the first voltage. The third switching device further includes a second output connected to a second end of the stator winding. A compressor crankcase heating control module controls the second and third switching devices to control compressor crankcase heating.

Claims

1. A compressor crankcase heating control system for a heat pump system, the compressor crankcase heating control system comprising:

a first switching device that includes a first input connected to a first power line, that includes a second input connected to a second power line, the first and second power lines for receiving a first voltage, and that selectively connects and disconnects the first and second inputs to and from first and second nodes, respectively;

a second switching device that includes a third input that is connected to the first node, that includes a fourth input that is connected to a third power line, and that includes a first output that is connected to a first end of a stator winding of an electric motor of a compressor;

a third switching device that includes a fifth input that is connected to the second node, that includes a sixth input that is connected to a fourth power line, the third and fourth power lines for receiving a second voltage that is less than the first voltage, and that includes a second output that is connected to a second end of the stator winding of the electric motor of the compressor; and

a compressor crankcase heating control module that controls the second and third switching devices.

2. The compressor crankcase heating control system of claim 1 wherein, when the first and second inputs are disconnected from the first and second nodes, respectively, the compressor crankcase heating control module selectively:

actuates the second switching device to connect the fourth input to the first output; and

actuates the third switching device to connect the sixth input to the second output.

3. The compressor crankcase heating control system of claim 2 wherein, when the first and second inputs are disconnected from the first and second nodes, respectively, the compressor crankcase heating control module selectively actuates the second and third switching devices based on at least one of a temperature of the compressor, an ambient temperature, a current date, and a current time.

4. The compressor crankcase heating control system of claim 2 wherein, when the first and second inputs are connected to the first and second nodes, respectively, the compressor crankcase heating control module:

actuates the second switching device to connect the third input to the first output; and

actuates the third switching device to connect the fifth input to the second output.

5. The compressor crankcase heating control system of claim 1 further comprising a thermostat that actuates the first switching device based on a temperature within a space and a predetermined temperature.

6. The compressor crankcase heating control system of claim 5 further comprising an indoor unit that includes an evaporator, a blower, and a transformer,

the transformer generating the second voltage based on a third voltage and outputting the second voltage to the thermostat.

7. The compressor crankcase heating control system of claim 6 wherein third voltage is:

less than the first voltage; and

greater than the second voltage.

8. The compressor crankcase heating control system of claim 5 wherein the second voltage is approximately 24 Volts.

9. The compressor crankcase heating control system of claim 1 further comprising:

an indoor unit that includes an evaporator, a blower, and a transformer, the transformer generating a third voltage based on a fourth voltage and outputting the third voltage; and

a thermostat that outputs the third voltage to the compressor crankcase heating control module,

wherein the compressor crankcase heating control module generates the second voltage based on the third voltage and outputs the second voltage.

10. The compressor crankcase heating control system of claim 9 wherein:

the third voltage is less than the fourth voltage; and

the second voltage is greater than the third voltage.

11. The compressor crankcase heating control system of claim 1 wherein the stator winding is a start winding.

12. The compressor crankcase heating control system of claim 1 wherein the stator winding is a run winding.

13. The compressor crankcase heating control system of claim 1 further comprising an electric motor of a condenser fan that is connected to the first and second nodes.

14. A compressor crankcase heating control system for a heat pump system, the compressor crankcase heating control system comprising:

a first switching device that includes a first input connected to a first power line, that includes a second input connected to a second power line, the first and second power lines for receiving a first voltage, and that selectively connects and disconnects the first and second inputs to and from first and second nodes, respectively;

a second switching device that includes a third input that is connected to the first node, that includes a fourth input that is connected to a third power line, and that includes a first output that is connected to;

a first end of a first winding of a stator of an electric motor of a compressor; and

a first end of a second winding of the stator of the electric motor of the compressor;

a third switching device that includes a fifth input that is connected to the second node, that includes a sixth input that is connected to a fourth power line, the third and fourth power lines for receiving a second voltage that is less than the first voltage, and that includes a second output that is connected to second ends of the first and second windings of the stator of the electric motor of the compressor; and

a compressor crankcase heating control module that controls the second and third switching devices.

15. The compressor crankcase heating control system of claim 14 wherein, when the first and second inputs are disconnected from the first and second nodes, respectively, the compressor crankcase heating control module selectively:

actuates the second switching device to connect the fourth input to the first output; and

actuates the third switching device to connect the sixth input to the second output.

16. The compressor crankcase heating control system of claim 15 wherein, when the first and second inputs are disconnected from the first and second nodes, respectively, the compressor crankcase heating control module selectively actuates the second and third switching devices based on at least one of a temperature of the compressor, an ambient temperature, a current date, and a current time.

17. The compressor crankcase heating control system of claim 15 wherein, when the first and second inputs are connected to the first and second nodes, respectively, the compressor crankcase heating control module:

actuates the second switching device to connect the third input to the first output; and

actuates the third switching device to connect the fifth input to the second output.

18. A heat pump system comprising:

first and second heat exchangers;

an expansion valve;

a compressor that includes an electric motor including a stator, the stator including a first winding and a second winding;

a first switching device that includes a first input connected to a first power line, that includes a second input connected to a second power line, the first and second power lines for receiving a first voltage, and that selectively connects and disconnects the first and second inputs to and from first and second nodes, respectively;

a second switching device that includes a third input that is connected to the first node, that includes a fourth input that is connected to a third power line, and that includes a first output that is connected to at least one of a first end of the first winding and a first end of the second winding;

a third switching device that includes a fifth input that is connected to the second node, that includes a sixth input that is connected to a fourth power line, the third and fourth power lines for receiving a second voltage that is less than the first voltage, and that includes a second output that is connected to a second end of the first winding and a second end of the second winding; and

a compressor crankcase heating control module that includes a processor and memory, the memory including instructions executed by the processor for;

when the first and second inputs are disconnected from the first and second nodes, respectively;

actuating the second switching device to connect the fourth input to the first output; and

actuating the third switching device to connect the sixth input to the second output; and

,

when the first and second inputs are connected to the first and second nodes, respectively;

actuating the second switching device to connect the third input to the first output; and

actuating the third switching device to connect the fifth input to the second output.

19. The heat pump system of claim 18 further comprising an indoor unit that includes a transformer and one of the first and second heat exchangers,

wherein the transformer generates the second voltage based on a third voltage.

20. The heat pump system of claim 18 further comprising an indoor unit that includes a transformer and one of the first and second heat exchangers,

wherein the transformer generates a third voltage based on a fourth voltage and outputs the third voltage to a thermostat, and

wherein the compressor crankcase heating control module generates the second voltage based on the third voltage.