System and method of mode-based compressor speed control for refrigerated vehicle compartment

• US 10,828,963 B2
• Filed: 06/28/2017
• Issued: 11/10/2020
• Est. Priority Date: 06/30/2016
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Vehr, Shawn W., Rozsnaki, Joseph J., Siefker, Louis
• Primary Examiner(s): Norman, Marc E
• Assistant Examiner(s): Sanks, Schyler S
• Application Number:
  US15/635,444
• Publication Number:
  US 20180001745A1
• Time in Patent Office: 1,231 Days
• CPC Class Codes: B60H 1/005 Regenerative cooling means, e.g. cold accumulators
• CPC Class Codes: B60H 1/3211 for increasing the efficiency of a vehicle refrigeration cycle
• CPC Class Codes: B60H 2001/3255 related to temperature
• CPC Class Codes: B60H 2001/3272 to control the revolving speed of a compressor
• CPC Class Codes: B60H 2001/3277 to control the air flow
• CPC Class Codes: B60H 2001/3282 to control the air flow
• CPC Class Codes: B60H 2001/3283 to control the refrigerant flow
• CPC Class Codes: B60H 2001/3289 Additional cooling source
• CPC Class Codes: F25B 2400/13 Economisers
• CPC Class Codes: F25B 2500/26 characterised by the startup of the refrigeration cycle
• CPC Class Codes: F25B 2600/0253 with variable speed
• CPC Class Codes: F25B 2600/11 Fan speed control
• CPC Class Codes: F25B 27/00 Machines, plants or systems, using particular sources of energy F25B30/06 takes precedence
• CPC Class Codes: F25B 2700/1931 Discharge pressures
• CPC Class Codes: F25B 2700/1933 Suction pressures
• CPC Class Codes: F25B 2700/2104 of an indoor room or compartment
• 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 2700/21163 of the refrigerant at the outlet of the condenser
• CPC Class Codes: F25B 2700/2117 of an evaporator
• CPC Class Codes: F25B 31/006 : Cooling of compressor or motor
• CPC Class Codes: F25B 49/022 : Compressor control arrangements
• CPC Class Codes: F25B 5/02 : arranged in parallel
• CPC Class Codes: F25D 11/006 : with cold storage accumulators
• CPC Class Codes: F25D 16/00 : Devices using a combination of a cooling mode associated with refrigerating machinery with a cooling mode not associated with refrigerating machinery
• CPC Class Codes: F25D 29/003 : for movable devices
• CPC Class Codes: Y02B 40/00 : Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers

Abstract

A system is provided that includes mode, shore power, engine, and battery modules. The mode module determines whether to operate in a shore power, engine, or battery mode based on parameters. The shore power module, while in the shore power mode, runs a compressor at a speed based on a temperature within a container of a vehicle and limits the speed to a first speed. A battery is charged based on utility power while in the shore power mode. The engine module, while in the engine mode, limits the compressor speed to a second speed. The battery, while in the engine mode, is charged based on power received from an alternator/generator. The battery module, while in the battery mode, limits the compressor speed to a third speed. While in the battery mode, the battery is not being charged based on power from a shore power source and the alternator/generator.

Claims

1. A system comprising:

a mode module configured to determine whether to operate in a shore power mode, an engine mode, or a battery mode based on a plurality of parameters;

a shore power module configured to, while operating in the shore power mode, set a compressor at a speed based on a temperature within a temperature-controlled container of a vehicle and limit the speed of the compressor to a first speed, wherein a first battery is charged based on power received from at least one of a utility power source and a solar power source while in the shore power mode;

an engine module configured to, while operating in the engine mode, set the speed of the compressor based on the temperature and limit the speed of the compressor to a second speed, wherein the first battery, while in the engine mode, is charged based on power received from at least one of an electrical source driven by an engine of the vehicle or the solar power source, wherein the second speed is less than or equal to the first speed, and wherein the electrical source is an alternator or a generator;

a battery module configured to, while operating in the battery mode, set the speed of the compressor based on the temperature and limit the speed of the compressor to a third speed, wherein, while in the battery mode, the first battery is not being charged based on power from (a) a shore power source, and (b) the electrical source from which power is received during the engine mode, and wherein the third speed is greater than 0 and less than the first speed and the second speed; and

a control module configured to (i) determine whether the system is operating in the shore power mode, the engine mode, or the battery mode, (ii) based on which one of the shore power mode, the engine mode, or the battery mode the system is operating in, perform at least one operation to determine whether to permit passage of a refrigerant through an evaporator and to determine whether to permit passage of the refrigerant through eutectic plates, and (iii) based on a result of the at least one operation, control passage of the refrigerant through at least one of the evaporator or the eutectic plates.

2. The system of claim 1, wherein the plurality of parameters comprise (i) a first parameter indicating whether shore power is connected, (ii) a second parameter indicating whether the alternator or the generator is ON and charging the first battery, and (iii) a suction pressure of the compressor.

3. The system of claim 1, wherein:

the plurality of parameters comprise a state of charge of one or more batteries; and

the one or more batteries include the first battery.

4. The system of claim 1, wherein the shore power module is configured to, while operating in the shore power mode:

if the temperature is less than a set point temperature, prevent the refrigerant from passing through eutectic plates and the evaporator; and

if the temperature is greater than the set point temperature, permit the refrigerant to pass through the eutectic plates or the evaporator.

5. The system of claim 4, wherein the shore power module is configured to, while operating in the shore power mode:

if the temperature is greater than the set point temperature for more than a predetermined period, permit passage of the refrigerant through the eutectic plates and the evaporator; and

if the temperature is greater than the set point temperature for less than the predetermined period, (i) permit passage of the refrigerant through the eutectic plates, and (ii) prevent passage of the refrigerant through the evaporator.

6. The system of claim 1, wherein the shore power module is configured to, while operating in the shore power mode and if the plurality of parameters satisfy a plurality of conditions, (i) run an evaporator fan, (ii) run a condenser fan, and (iii) permit passage of the refrigerant through eutectic plates and the evaporator.

7. The system of claim 1, wherein the shore power module is configured to (i) if the plurality of parameters satisfy a plurality of conditions, set the speed of the compressor to 0 for a first predetermined period, and (ii) subsequent to the first predetermined period, set the speed of the compressor to a speed greater than 0for a second predetermined period.

8. The system of claim 7, wherein the shore power module is configured to (i) if an ambient temperature is greater than a predetermined temperature, set the speed of the compressor to a speed less than or equal to the first speed, and (ii) if the ambient temperature is less than the predetermined temperature, set the speed of the compressor to the third speed or a speed less than the first speed.

9. The system of claim 8, wherein:

the shore power module is configured to (i) if the ambient temperature is less than the predetermined temperature, set the speed of the compressor to a speed less than or equal to the third speed for a third predetermined period, and (ii) subsequent to the third predetermined period, set the speed of the compressor to a speed less than or equal to the first speed; and

the third predetermined period is less than the second predetermined period.

11. The system of claim 1, wherein the engine module is configured to, while operating in the engine mode:

if the temperature is less than a set point temperature, prevent the refrigerant from passing through eutectic plates and the evaporator; and

if the temperature is greater than the set point temperature, permit the refrigerant to pass through the eutectic plates or the evaporator.

12. The system of claim 11, wherein the engine module is configured to, while operating in the engine mode:

if the temperature is greater than the set point temperature for more than a predetermined period, permit passage of the refrigerant through the eutectic plates and the evaporator; and

if the temperature is greater than the set point temperature for less than the predetermined period, (i) permit passage of the refrigerant through the eutectic plates, and (ii) prevent passage of the refrigerant through the evaporator.

13. The system of claim 1, wherein the battery module is configured to, while operating in the battery mode:

if the temperature is less than a set point temperature, prevent the refrigerant from passing through eutectic plates and the evaporator; and

if the temperature is greater than the set point temperature, permit the refrigerant to pass through the eutectic plates or the evaporator.

14. The system of claim 13, wherein the battery module is configured to, while operating in the battery mode:

if the temperature is greater than the set point temperature for more than a predetermined period, permit passage of the refrigerant through the eutectic plates and the evaporator; and

if the temperature is greater than the set point temperature for less than the predetermined period, (i) permit passage of the refrigerant through the eutectic plates, and (ii) prevent passage of the refrigerant through the evaporator.

15. The system of claim 1, wherein the control module configured to, while in at least one of the shore power mode, the engine mode, or the battery mode:

shut off an evaporator fan if a door of the temperature-controlled container is in an open state; and

run the evaporator fan based on the temperature when the door is in a closed state.

16. The system of claim 1, wherein at least one of:

the shore power module is configured to determine the first speed based on a load on the compressor;

the engine module is configured to determine the second speed based on the load on the compressor; and

the battery module is configured to determine the third speed based on the load on the compressor.

17. The system of claim 1, further comprising:

the compressor;

eutectic plates;

the evaporator;

an evaporator fan;

a condenser fan; and

a plurality of valves,

wherein the control module configured to, based on whether the system is operating in the shore power mode, the engine mode or the battery mode, control operation of the evaporator fan and the condenser fan and states of the plurality of valves, wherein controlling states of the plurality of valves controls flow of the refrigerant through the eutectic plates and the evaporator.

18. The system of claim 1, wherein:

wherein the first battery is charged based on power received from the utility power source while in the shore power mode; and

the first battery, while in the engine mode, is charged based on power received from the electrical source driven by the engine of the vehicle.

33. The system of claim 1, wherein the control module is configured to:

based on which one of the shore power mode, the engine mode, or the battery mode the system is operating, (a) perform a first operation to determine whether to permit passage of the refrigerant through the evaporator, and (b) perform a second operation to determine whether to permit passage of the refrigerant through eutectic plates, wherein the at least one operation includes the first operation and the second operation;

based on a result of the first operation, permit passage of the refrigerant through the evaporator; and

based on a result of the second operation, permit passage of the refrigerant through the eutectic plates.

34. The system of claim 1, wherein the control module is configured to:

while in the shore power mode, determine an ambient temperature, and based on the ambient temperature, control the speed of the compressor; and

while in the engine mode and the battery mode, control the speed of the compressor independent of the ambient temperature.

35. The system of claim 1, wherein the control module is configured to:

while in the engine mode and when the temperature is less than or within a predetermined range of a set temperature, run a condenser fan and permit passage of the refrigerant to the eutectic plates and an expansion valve; and

while in the battery mode and when the temperature is less than or within the predetermined range of the set temperature, shut off the condenser fan and prevent passage of the refrigerant to the eutectic plates and the expansion valve.

36. The system of claim 35, wherein the control module is configured to while in the engine mode and the battery mode and when the temperature is less than or within the predetermined range of the set temperature, shut off an evaporator fan and prevent passage of the refrigerant to the evaporator.

38. The system of claim 15, wherein the control module is configured to:

if the door is in the open state and the compressor has been running for a predetermined period, maintain the compressor and a condenser fan in an ON state and prevent passage of the refrigerant to the evaporator; and

if the door is in the open state and the compressor has not been running for the predetermined period, shut off the compressor and the condenser fan and prevent passage of the refrigerant to the evaporator.

40. The system of claim 1, wherein the refrigerant is a fluid.

10. A system comprising:

a mode module configured to determine whether to operate in a shore power mode, an engine mode, or a battery mode based on a plurality of parameters;

a shore power module configured to, while operating in the shore power mode, set a compressor at a speed based on a temperature within a temperature-controlled container of a vehicle and limit the speed of the compressor to a first speed, wherein a first battery is charged based on power received from at least one of a utility power source and a solar power source while in the shore power mode;

an engine module configured to, while operating in the engine mode, set the speed of the compressor based on the temperature and limit the speed of the compressor to a second speed, wherein the first battery, while in the engine mode, is charged based on power received from at least one of an electrical source driven by an engine of the vehicle or the solar power source, wherein the second speed is less than or equal to the first speed, and wherein the electrical source is an alternator or a generator; and

a battery module configured to, while operating in the battery mode, set the speed of the compressor based on the temperature and limit the speed of the compressor to a third speed, wherein, while in the battery mode, the first battery is not being charged based on power from (a) a shore power source, and (b) the electrical source from which power is received during the engine mode, and wherein the third speed is greater than 0 and less than the first speed and the second speed,

wherein

the shore power module is configured to, while in the shore power mode and based on a suction pressure of the compressor, operate in a pulldown maintenance mode to pulldown a temperature of eutectic plates; and

the pulldown maintenance mode comprises, based on the temperature of the temperature-controlled container, switching between (i) preventing passage of a refrigerant to the eutectic plates and an evaporator, (ii) permitting passage of the refrigerant through the eutectic plates and preventing passage of the refrigerant through the evaporator, and (iii) permitting passage of the refrigerant through the eutectic plates and the evaporator.

37. The system of claim 10, further comprising a control module, wherein:

the shore power module determines whether the suction pressure is less than or equal to a predetermined suction pressure; and

the control module is configured to, based on the temperature and a compressor ON time, control the compressor, an evaporator fan, a condenser fan, passage of the refrigerant through eutectic plates, and passage of the refrigerant through an expansion valve.

19. A method comprising:

determining whether to operate in a shore power mode, an engine mode or a battery mode based on a plurality of parameters;

while operating in the shore power mode, setting a compressor at a speed based on a temperature within a temperature-controlled container of a vehicle and limiting the speed of the compressor to a first speed, wherein a first battery is charged based on power received from at least one of a utility power source and a solar power source while in the shore power mode;

while operating in the engine mode, setting the speed of the compressor based on the temperature and limiting the speed of the compressor to a second speed, wherein the first battery, while in the engine mode, is charged based on power received from at least one of an alternator, a generator or the solar power source, and wherein the second speed is equal to or less than the first speed;

while operating in the battery mode, setting the speed of the compressor based on the temperature and limiting the speed of the compressor to a third speed, wherein, while in the battery mode, the first battery is not being charged based on power from (i) a shore power source, and (ii) the alternator or the generator from which power is received during the engine mode, and wherein the third speed is greater than 0 and less than the first speed and the second speed;

determining whether a system is operating in the shore power mode, the engine mode, or the battery mode;

based on which one of the shore power mode, the engine mode, or the battery mode the system is operating in, performing at least one operation to determine whether to permit passage of a refrigerant through an evaporator and to determine whether to permit passage of the refrigerant through eutectic plates; and

based on a result of the at least one operation, controlling passage of the refrigerant through at least one of the evaporator or the eutectic plates.

20. The method of claim 19, wherein the plurality of parameters comprise (i) a first parameter indicating whether shore power is connected, (ii) a second parameter indicating whether the alternator or the generator is ON and charging the first battery, and (iii) a suction pressure of the compressor.

21. The method of claim 19, wherein:

the plurality of parameters comprise a state of charge of one or more batteries; and

the one or more batteries include the first battery.

22. The method of claim 19, wherein while operating in the shore power mode:

based on the temperature being less than a set point temperature, preventing the refrigerant from passing through eutectic plates and the evaporator; and

based on the temperature being greater than the set point temperature, permitting the refrigerant to pass through the eutectic plates or the evaporator.

23. The method of claim 22, wherein while operating in the shore power mode:

based on the temperature being greater than the set point temperature for more than a predetermined period, permitting passage of the refrigerant through the eutectic plates and the evaporator; and

based on the temperature being greater than the set point temperature for less than the predetermined period, (i) permitting passage of the refrigerant through the eutectic plates, and (ii) preventing passage of the refrigerant through the evaporator.

24. The method of claim 19, further comprising, while operating in the shore power mode, (i) based on the plurality of parameters satisfying a plurality of conditions, setting the speed of the compressor to 0 for a first predetermined period, and (ii) subsequent to the first predetermined period, setting the speed of the compressor to a speed greater than 0 for a second predetermined period.

25. The method of claim 24, further comprising, while operating in the shore power mode, (i) based on an ambient temperature being greater than a predetermined temperature, setting the speed of the compressor to a speed less than or equal to the first speed, and (ii) based on the ambient temperature being less than the predetermined temperature, setting the speed of the compressor to the third speed or a speed less than the first speed.

26. The method of claim 25, further comprising, while operating in the shore power mode, (i) based on the ambient temperature being less than the predetermined temperature, setting the speed of the compressor to a speed less than or equal to the third speed for a third predetermined period, and (ii) subsequent to the third predetermined period, setting the speed of the compressor to a speed less than or equal to the first speed, wherein the third predetermined period is less than the second predetermined period.

27. The method of claim 19, further comprising, based on a suction pressure of the compressor, operating in a pulldown maintenance mode, wherein the pulldown maintenance mode comprises, based on the temperature, switching between (i) preventing passage of the refrigerant to eutectic plates and the evaporator, (ii) permitting passage of the refrigerant through the eutectic plates and preventing passage of the refrigerant through the evaporator, and (iii) permitting passage of the refrigerant through the eutectic plates and the evaporator.

28. The method of claim 27, further comprising:

adjusting the speed of the compressor while in each of the shore power mode, the engine mode and the battery mode; and

adjusting speeds of an evaporator fan and a condenser fan while in each of the shore power mode, the engine mode and the battery mode.

29. The method of claim 19, further comprising while operating in the engine mode:

based on the temperature being less than a set point temperature, preventing the refrigerant from passing through eutectic plates and the evaporator; and

based on the temperature being greater than the set point temperature, permitting the refrigerant to pass through the eutectic plates or the evaporator.

30. The method of claim 29, further comprising, while operating in the engine mode:

based on the temperature being greater than the set point temperature for more than a predetermined period, permitting passage of the refrigerant through the eutectic plates and the evaporator; and

based on the temperature being greater than the set point temperature for less than the predetermined period, (i) permitting passage of the refrigerant through the eutectic plates, and (ii) preventing passage of the refrigerant through the evaporator.

31. The method of claim 19, further comprising while operating in the battery mode:

based on the temperature being less than a set point temperature, preventing the refrigerant from passing through eutectic plates and the evaporator; and

based on the temperature being greater than the set point temperature, permitting the refrigerant to pass through the eutectic plates or the evaporator.

32. The method of claim 19, further comprising while in at least one of the shore power mode, the engine mode, or the battery mode:

shutting off an evaporator fan if a door of the temperature-controlled container is in an open state; and

running the evaporator fan based on the temperature when the door is in a closed state.

39. The method of claim 19, further comprising:

based on the operating mode, (a) performing a first operation to determine whether to permit passage of the refrigerant through the evaporator, and (b) performing a second operation to determine whether to permit passage of the refrigerant through eutectic plates;

based on a result of the first operation, permitting passage of the refrigerant through the evaporator; and

based on a result of the second operation, permitting passage of the refrigerant through the eutectic plates.

41. The method of claim 19, further comprising, based on the temperature, switching between (i) preventing passage of the refrigerant to eutectic plates and the evaporator, (ii) permitting passage of the refrigerant through the eutectic plates and preventing passage of the refrigerant through the evaporator, and (iii) permitting passage of the refrigerant through the eutectic plates and the evaporator.