Cost-effective remote monitoring, diagnostic and system health prediction system and method for vapor compression and heat pump units based on compressor discharge line temperature sampling

• US 9,424,519 B1
• Filed: 07/09/2015
• Issued: 08/23/2016
• Est. Priority Date: 09/07/2011
• Status: Active Grant

• Current Assignee: Mainstream Engineering Coporation
• Original Assignee: Mainstream Engineering Coporation
• Inventors: Scaringe, Robert P., Roth, Robert Paul, Thomas, Erik P., Carff, Chad L., Lambert, Daniel
• Primary Examiner(s): Bradford, Jonathan
• Application Number:
  US14/795,347
• Time in Patent Office: 411 Days
• US Class Current: 1/1
• CPC Class Codes: A61K 48/00 Medicinal preparations containing genetic material which is inserted into cells of the living body to treat genetic diseases; Gene therapy
• 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 11/36 to leakage of heat-exchange fluid
• CPC Class Codes: F24F 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/58 using Internet communication
• CPC Class Codes: F24F 11/62 characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
• CPC Class Codes: F24F 11/63 Electronic processing
• CPC Class Codes: F24F 2140/00 Control inputs relating to system states
• CPC Class Codes: F25B 2345/003 Control issues for charging or collecting refrigerant to or from a cycle
• CPC Class Codes: F25B 2500/07 Exceeding a certain pressure value in a refrigeration component or cycle
• CPC Class Codes: F25B 2500/08 Exceeding a certain temperature value in a refrigeration component or cycle
• CPC Class Codes: F25B 2500/222 Detecting refrigerant leaks
• CPC Class Codes: F25B 2500/24 Low amount of refrigerant in the system
• CPC Class Codes: F25B 2600/05 Refrigerant levels
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2600/19 Refrigerant outlet condenser temperature
• CPC Class Codes: F25B 2700/04 Refrigerant level
• CPC Class Codes: F25B 2700/151 of the compressor motor
• CPC Class Codes: F25B 2700/2102 at the outlet of the gas cooler
• CPC Class Codes: F25B 2700/2106 of fresh outdoor air
• CPC Class Codes: F25B 2700/21151 : at the suction side of the compressor
• CPC Class Codes: F25B 2700/21152 : at the discharge side of the compressor
• CPC Class Codes: F25B 2700/2116 : of a condenser
• CPC Class Codes: F25B 2700/21162 : of the refrigerant at the inlet of the condenser
• CPC Class Codes: F25B 2700/21163 : of the refrigerant at the outlet of the condenser
• CPC Class Codes: F25B 49/005 : of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: F25B 49/02 : for compression type machines, plants or systems
• CPC Class Codes: F25B 49/022 : Compressor control arrangements
• CPC Class Codes: F25B 49/027 : Condenser control arrangements
• CPC Class Codes: G06N 5/04 : Inference or reasoning models
• CPC Class Codes: G08B 21/187 : Machine fault alarms

Abstract

A diagnostic monitoring system and method is employed for one or more vapor compression systems such as air conditioners and heat pumps having a compressor, an indoor air handler fan coil and an outdoor condensor. Temperature, voltage and current sensors are provided at the outdoor condensor to determine that at least one vapor compression system is operating properly. Data obtained from the sensors is wirelessly transmitted to a receiving-device for use by the systems'"'"' custodian or repair service provider and includes information concerning an occurrence of periods when one or more of the vapor compression systems are operating at an abnormal state.

Claims

1. A monitoring system for at least one vapor-compression system having an outdoor section comprised of a compressor and a condenser, wherein the monitoring system comprises three sensors associated with only the outdoor section, one of the sensors being a current measuring sensor and two of the sensors being voltage measuring sensors, so that a processed output of measured values of the current and voltage sensors in only the outdoor section is able by itself to predict failed or improper compressor operation based on a comparison of one of a previously obtained measured performance curve, a table of values and an equation, each as a function of outdoor ambient air temperature obtained during normal operation of the vapor-compression system, in relation to the measured current and voltage sensor values.

2. The monitoring system of claim 1, wherein the failed or improper compressor operation is determined when one of the predicted sensor values is a one of an overall current or compressor current, and the other sensor values are the start winding voltage and the run winding voltage.

3. The monitoring system of claim 1, wherein a predicted normal ratio of start-winding voltage to run-winding voltage or run-winding voltage to start-winding voltage as a function of current draw of the compressor is derived from said at least one of previously obtained normal operating performance curves, a table of values and an equation, and compared to a measured value of the ratio at a measured current draw to determine occurrences when the at least one vapor compression system is operating with a failed or improper compressor performance.

4. The monitoring system of claim 2, wherein a predicted normal ratio of start-winding voltage to run-winding voltage or run-winding voltage to start-winding voltage as a function of current draw of the compressor derived from at least one of previously obtained normal operating performance curves, a table of values and an equation, and compared to a measured value of the ratio at a measured current draw, to determine occurrences when the at least one vapor compression system is operating with a degraded or failed run capacitor.

5. The monitoring system of claim 4, wherein a run capacitance in the unit is projected to be undesirably low when a measured ratio for the measured current draw is more than approximately 5% from the predicted normal ratio.

6. The monitoring system of claim 1, wherein data concerning an occurrence of periods when the at least one vapor compression system is operating with a failed or improper compressor is transmitted via the Internet to at least one of the systems custodian and a repair service provider.

7. The monitoring system of claim 4, wherein data concerning an occurrence of periods when the at least one vapor compression system is operating with a degraded or failed run capacitor is transmitted via the Internet to at least one of the systems custodian and a repair service provider.