System for remote refrigeration monitoring and diagnostics

• US 7,644,591 B2
• Filed: 09/14/2004
• Issued: 01/12/2010
• Est. Priority Date: 05/03/2001
• Status: Expired due to Fees

• Current Assignee: Emerson Climate Technologies Retail Solutions Incorporated (Emerson Electric Company)
• Original Assignee: Emerson Retail Services, Inc. (Emerson Electric Company)
• Inventors: Mathews, Thomas J, Singh, Abtar, Wickberg, Paul, Starling, Neal
• Primary Examiner(s): Norman; Marc E
• Application Number:
  US10/940,877
• Publication Number:
  US 20050028539A1
• Time in Patent Office: 1,946 Days
• Field of Search: 621/25, 621/26, 621/27, 621/29, 621/30, 622/98, 236/51, 236/94, 165/11.1, 165/11.2, 702/182, 702/183, 702/184, 702/185, 340/3.1, 340/3.43, 340/3.44, 700/276, 700/277, 700/278
• US Class Current: 62/127
• CPC Class Codes: A23G 9/00 Frozen sweets, e.g. ice confectionery, ice-cream; Mixtures therefor
• CPC Class Codes: A23L 3/00 Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs preserving foods or foodstuffs in association with packaging B65B55/00
• CPC Class Codes: A23L 3/36 Freezing; Subsequent thawing; Cooling
• CPC Class Codes: F25B 2400/075 with parallel compressors
• CPC Class Codes: F25B 2400/22 Refrigeration systems for supermarkets
• CPC Class Codes: F25B 2600/07 Remote controls
• CPC Class Codes: F25B 2700/195 of the condenser
• CPC Class Codes: F25B 49/005 of safety devices F25B49/02 and F25B49/04 take precedence
• CPC Class Codes: F25B 5/00 Compression machines, plants or systems, with several evaporator circuits, e.g. for varying refrigerating capacity with cascade operation F25B7/00
• CPC Class Codes: F25D 2400/36 Visual displays
• CPC Class Codes: F25D 2700/12 Sensors measuring the inside temperature
• CPC Class Codes: F25D 2700/14 Sensors measuring the temperature outside the refrigerator or freezer
• CPC Class Codes: F25D 2700/16 Sensors measuring the temperature of products
• CPC Class Codes: F25D 29/00 Arrangement or mounting of control or safety devices
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 2219/2642 Domotique, domestic, home control, automation, smart house
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A system for monitoring and managing a refrigeration system of a remote location includes a management center in communication with a refrigeration system through a communication network. The management center receives performance information of the refrigeration system. The management center employs software modules to analyze the performance information; diagnose system conditions; provide alarms for food safety issues, food quality issues and refrigeration system component failure; indicate maintenance conditions; and configure the refrigeration system.

Claims

1. A management center configured for communication with a refrigeration system controller through a communication network, the management center comprising a processor and a database storing a plurality of refrigeration system maintenance procedures, and configured to receive operational data regarding refrigeration system performance, to store historical sets of operational data as stored operational data in said database, to evaluate said received operational data in comparison to said stored operational data with algorithms executed by said processor, to determine projected operational data based on said received operational data and said stored operational data, and to select a refrigeration system maintenance procedure for at least one refrigeration system component from said plurality of refrigeration system maintenance procedures based on said evaluation, wherein said database stores said projected data.

2. The management center according to claim 1, wherein said processor is operable to configure said refrigeration system controller.

3. The management center according to claim 1, wherein said processor is operable to initially configure said refrigeration system controller.

4. The management center according to claim 1, wherein said projected operational data includes data generated by said algorithms based on at least one of said stored operational data and published typical data.

5. The management center of claim 4 further comprising a user interface for displaying said projected operational data

6. The management center according to claim 1, further including diagnostic software for analyzing refrigeration system performance.

7. The management center according to claim 1, further including a post-processing system configured for communication with the refrigeration system controller and operable to gather refrigeration system performance data.

8. The management center according to claim 7, wherein said post-processing system includes diagnostic software operable to analyze said refrigeration system performance data.

9. The management center according to claim 8, wherein said diagnostic software is operable to determine refrigeration system maintenance procedures.

10. The management center according to claim 1, further comprising a remote computer in communication with the management center and the refrigeration system controller, and capable of monitoring said refrigeration system performance.

11. The management center according to claim 1, further comprising a graphical user interface operable to display or compare subsets of said stored operational data against other subsets of said stored operational data.

12. The management center according to claim 1, wherein said received operational data and said stored operational data each include at least one of temperature and pressure data.

13. The management center according to claim 12, wherein said temperature data includes at least one of case temperature or temperatures, ambient temperature, and condenser temperature.

14. The management center according to claim 12, wherein said pressure data includes at least one of suction pressure and discharge pressure.

15. The management center according to claim 1, wherein said plurality of refrigeration system maintenance procedures include routine refrigeration system maintenance procedures.

16. The management center according to claim 1, further comprising an alarming function selectively providing an alert based on said evaluation of said received operational data and said stored operational data.

17. The management center according to claim 1 wherein said received operational data and said stored operational data each include condenser temperature difference data corresponding to a difference between a condenser temperature and an ambient temperature and wherein said selected refrigeration system maintenance procedure includes cleaning a refrigeration system condenser when said condenser temperature difference data indicates that said difference is increasing over time.

18. The management center according to claim 1 wherein said received operational data and said stored operational data each include superheat data corresponding to a compressor suction manifold superheat and a compressor discharge header superheat and wherein said selected refrigeration system maintenance procedure indicates a liquid refrigerant flood back condition when at least one of said compressor suction manifold superheat and said compressor discharge header superheat decreases more than a predetermined amount.

19. The management center according to claim 1 wherein said received operational data and said stored operational data each include superheat data corresponding to a compressor suction manifold superheat and a compressor discharge header superheat and wherein said selected refrigeration system maintenance procedure indicates a severe liquid refrigerant flood back condition when both said compressor suction manifold superheat and said compressor discharge header superheat decrease more than a predetermined amount.

20. The management center of claim 1, further comprising a user interface for displaying said projected operational data.

21. The management center of claim 20, wherein said user interface displays a comparison of said projected operational data with actual operational data.

22. A system comprising a management center including a maintenance module, a work order module and a data warehouse, said management center configured to receive operational data regarding refrigeration system performance and to monitor a refrigeration system at a remote location, said data warehouse configured to store historical data sets of said operational data and a plurality of refrigeration system maintenance procedures, said maintenance module configured to compare said received operational data to said stored historical data sets, to determine projected operational data based on said received operational data and said stored historical data sets, and to select a refrigeration system maintenance procedure for at least one refrigeration system component from said plurality of refrigeration system maintenance procedures based on said comparison and said work order module configured to generate a work order corresponding to said selected refrigeration system maintenance procedure, wherein said data warehouse stores said projected operational data.

23. The system of claim 22, further comprising a remote computer configured to communicate with said management center and said refrigeration system.

24. The system of claim 22, wherein said plurality of refrigeration system maintenance procedures include routine refrigeration system maintenance procedures.

25. The system of claim 22, wherein said management center includes an alarming function providing notification based on analysis of said received operational data and said stored historical data sets.

26. The system of claim 22, wherein said management center includes a system configuration tool.

27. The system of claim 26, wherein said system configuration tool is configured to provide initial configuration of a refrigeration system controller.

28. The system of claim 22, wherein said work-order module is configured to track refrigeration system work orders.

29. The system of claim 22 wherein said received operational data and said stored historical data sets each include condenser temperature difference data corresponding to a difference between a condenser temperature and an ambient temperature and wherein said selected refrigeration system maintenance procedure includes cleaning a refrigeration system condenser when said condenser temperature difference data indicates that said difference is increasing over time.

30. The system of claim 22 wherein said received operational data and said stored historical data sets each include superheat data corresponding to a compressor suction manifold superheat and a compressor discharge header superheat and wherein said selected refrigeration system maintenance procedure indicates a liquid refrigerant flood back condition when at least one of said compressor suction manifold superheat and said compressor discharge header superheat decreases more than a predetermined amount.

31. The system of claim 22 wherein said received operational data and said stored historical data sets each include superheat data corresponding to a compressor suction manifold superheat and a compressor discharge header superheat and wherein said selected refrigeration system maintenance procedure indicates a severe liquid refrigerant flood back condition when both said compressor suction manifold superheat and said compressor discharge header superheat decrease more than a predetermined amount.