Power savings apparatus for transport refrigeration system, transport refrigeration unit, and methods for same

• US 9,140,489 B2
• Filed: 08/06/2010
• Issued: 09/22/2015
• Est. Priority Date: 08/10/2009
• Status: Active Grant

• Current Assignee: Carrier Corporation (Carrier Global Corporation)
• Original Assignee: Carrier Corporation (Carrier Global Corporation)
• Inventors: Duraisamy, Suresh, Cresswell, Kenneth
• Primary Examiner(s): Bradford, Jonathan
• Application Number:
  US13/389,030
• Publication Number:
  US 20120137713A1
• Time in Patent Office: 1,873 Days
• Field of Search: 621/26, 621/29, 621/32, 621/57, 622/31, 622/39, 165/200
• US Class Current: 1/1
• CPC Class Codes: B60H 1/00014 for load cargos on load transporting vehicles
• CPC Class Codes: B60P 3/20 Refrigerated goods vehicles air treatment of goods space B60H; air-conditioning means for freight cars, isothermic wagons B61D27/0027; superstructures for refrigerated goods vehicles B62D33/048
• CPC Class Codes: F25B 2500/05 Cost reduction
• CPC Class Codes: F25B 2500/18 Optimization, e.g. high integration of refrigeration components
• CPC Class Codes: F25B 2500/19 Calculation of parameters
• CPC Class Codes: F25B 2600/01 Timing
• CPC Class Codes: F25B 2700/21172 at the inlet
• CPC Class Codes: F25B 2700/21173 at the outlet
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems
• CPC Class Codes: F25D 29/003 for movable devices

Abstract

Embodiments of systems, apparatus, and/or methods can control conditions such as temperature within a container of a transport refrigeration system. Embodiments can include a controller for controlling the transport refrigeration system to reduce power consumption. Embodiments of systems, apparatus, and/or methods for operating the same can control cycling of a transport refrigeration unit to conserve power where a subsequent cycle time in a power savings mode is based on at least one previous cycle time. In addition, components can be enabled based on monitored conditions to reduce power consumption.

Claims

1. A transport refrigeration unit for regulating the temperature of an enclosed volume, the transport refrigeration unit comprising:

a refrigeration module operatively coupled to said enclosed volume, said refrigeration module including;

a supply port to output air to said enclosed volume at a supply temperature;

a return port to return air from said enclosed volume to the refrigeration module at a return temperature;

at least one component configured to operate in a first cooling mode and an economy mode; and

a controller configured to change a length of a subsequent operating interval for said at least one component in said economy mode based on at least one previous operating interval of said at least one component in said economy mode.

2. The transport refrigeration unit of claim 1, said controller configured to set a second interval in said economy mode to be less than said first interval when said supply temperature is above a prescribed threshold after exiting a first interval in said economy mode and to set said second interval in said economy mode to be greater than said first interval when said supply temperature is below said prescribed threshold after exiting the first interval in said economy mode.

3. The transport refrigeration unit of claim 1, said controller configured to set a next (n+1) interval in said economy mode equal to one of 90% of a current (n) interval, said current (n) interval minus a prescribed period of time, or said current (n) interval minus 5 minutes when said supply temperature is above a prescribed threshold after exiting the current (n) interval in said economy mode, said controller configured to set said next (n+1) interval in said economy mode equal to one of 110% of said current (n) interval, said current (n) interval plus said prescribed period of time, or said current (n) interval plus 5 minutes when said supply temperature is below said prescribed threshold after exiting the current (n) interval in said economy mode.

4. The transport refrigeration unit of claim 1, said controller configured to set an averaged next (n+1) interval in said economy mode by averaging m previous intervals in economy mode, wherein said averaged next (n+1) interval in said economy mode is equal to ((said next (n+1) interval in economy mode + a current (n) interval in said economy mode + . . . + said mth previous (n+1−

m) interval in said economy mode)/m).

5. The transport refrigeration unit of claim 1, said controller configured to set an averaged (n+1) interval in said economy mode by weight averaging m previous intervals in economy mode, wherein said averaged (n+1) interval in said economy mode is equal to (((w1*(n+1) interval)+(w2*(n) interval) + . . . + (wm*(n+1−

m) interval))/m) where w1, w2, . . . wm are weighting factors and w1>

w2>

. . . >

w(m−

1)>

wm.

6. The transport refrigeration unit of claim 1, said controller configured to determine an increase in said supply temperature that occurred during a first interval in the economy mode as a percentage of a prescribed increase range, wherein an inverse of the percentage is used to modify a length of said first interval to determine a length of a second interval in the economy mode.

7. The transport refrigeration unit of claim 1, said controller configured to determine an increase in said supply temperature that occurred during a first interval in the economy mode as a percentage of a prescribed increase range, wherein the percentage is a linear multiplier, nonlinear multiplier or linear function of a length of said first interval to set a length of a second interval in the economy mode.

8. The transport refrigeration unit of claim 1, said controller configured to determine a prescribed temperature or a temperature difference between said supply temperature and said prescribed temperature in the first cooling mode after exiting a first interval in said economy mode, said controller configured—

to determine said temperature difference a prescribed time after exiting said first interval in the economy mode, intermittently after exiting said first interval, repeatedly after exiting said first interval, or periodically after exiting said first interval, said controller configured to set a length of a second interval in said economy mode greater than said first interval when said temperature difference is below a prescribed threshold, said controller configured to set said second interval in said economy mode less than said first interval when said temperature difference is above the prescribed threshold.

9. The transport refrigeration unit of claim 1, said controller configured to determine a length of a next interval in the economy mode for said component based on (i) a determined length of one or more selected previous operation intervals in the economy mode for said component and (ii) a temperature difference between said supply temperature and said return temperature determined in the first cooling mode after leaving the economy mode in one previous operation intervals, or (iii) a determined refrigeration load.

10. The transport refrigeration unit of claim 9, wherein said determined length is an averaged length of each of a first set of immediately previous operation intervals in the economy mode for said component, an averaged length of each of a second set of selected previous operation intervals having similar ambient characteristics or an averaged length of each of a third set of selected previous operation intervals in the economy mode for said component,

and wherein said determined refrigeration load is based on at least one of (i) ambient conditions, changes to a current cargo, changes to a current enclosed volume, respiration load of the current cargo or heat generated by said component.

11. The transport refrigeration unit of claim 1, said refrigeration module including:

a compressor having an input and an output;

a condenser heat exchanger unit operatively coupled to said output;

an evaporator heat exchanger unit operatively coupled to said input;

a condenser fan disposed proximate to said condenser heat exchanger unit; and

an evaporator fan disposed proximate to said evaporator heat exchanger unit, said controller configured to regulate the operation of said compressor, said condenser fan, and said evaporator, said component being at least one of said compressor, said condenser fan, or said evaporator fan, said controller configured to determine a temperature difference between said supply temperature and said return temperature in the first mode after exiting a first interval in said economy mode.

12. The transport refrigeration unit of claim 1, wherein said economy mode is first power savings mode where the component is off or a second power savings mode where the component operates in a low speed mode, and the first mode is an operational mode or full cool mode.

13. The transport refrigeration unit of claim 12, wherein upon exiting the first power savings mode, a characteristic of a motor of a heat exchanger fan unit is monitored, and wherein a compressor is enabled based on the monitored characteristic.

14. The transport refrigeration unit of claim 13, wherein the monitored characteristic is current drawn by the motor, wherein the motor is a condenser fan motor, and wherein the compressor is enabled when the current drawn is less than a prescribed value, less than 2 amps, less than 1.5 amps or is less than 1 amp.

15. The transport refrigeration unit of claim 1, wherein the controller is configured to operate the component in the first mode until a sensed temperature is less than a first selected value and to exit the economy mode when the sensed temperature is not less than a second selected value.

16. The transport refrigeration unit of claim 1, said controller configured to selectively operate said refrigeration module in said economy mode when Ts<

Tc1, where Ts is a supply temperature and Tc1 is a set value or when Tr<

Tc2, where Tr is a return temperature and Tc2 is a set value.

17. A computer program product comprising a non-transitory computer usable storage medium to store a computer readable program that, when executed on a computer, configures the computer to perform operations to operate a transport refrigeration unit, the operations comprising:

operate the transport refrigeration unit in a power savings mode for a first period;

switch the transport refrigeration unit to operate in a first mode; and

operate the transport refrigeration unit in the power saving mode for a second period in the power savings mode having a different length than the first period in the power savings mode, wherein the length of the second period is a function of the first period.

18. The computer program product of claim 17, wherein the computer readable program, when executed on the computer, configures the computer to perform operations, the operations comprising:

set the second period in said power saving mode less than said first period when said supply temperature is above a prescribed threshold after exiting the first period in said power saving mode; and

set said second period in said power saving mode greater than said first period when said supply temperature is below said prescribed temperature after exiting the first period in said power saving mode.

19. A method of operating a transport refrigeration unit, comprising:

operating the transport refrigeration unit in a power savings mode for a first cycle;

switching the transport refrigeration unit to operate in a first mode; and

operating the transport refrigeration unit in the power saving mode for a second cycle having a different length than the first cycle in the power savings mode, wherein the length of the second cycle is based on a length of the first cycle.