Systems and methods for protecting hermetic compressor electrical feedthroughs

Abstract

A method for feedthrough protection and overcurrent protection of a hermetic compressor in a transport climate control system is provided. The transport climate control system includes a climate control circuit with a hermetic compressor. The hermetic compressor includes a housing and an electric motor located within the housing. The method includes operating the hermetic compressor to compress a working fluid by providing power to the electric motor of the hermetic compressor via a hermetic electrical feedthrough within the housing of the hermetic compressor. The method also includes detecting an operating parameter of the hermetic electrical feedthrough and determining whether the hermetic electrical feedthrough is in a melted condition based on the detected operating parameter. Furthermore, the method includes adjusting operation of the climate control circuit until the hermetic electrical feedthrough is no longer in the melted condition if the hermetic electrical feedthrough is determined to be in the melted condition.

Description

Technical Field

[0001] The present disclosure relates generally to transportation climate control systems. More particularly, the present disclosure relates to feedthrough protection and overcurrent protection for hermetic compressors used in transportation climate control systems. Background Art

[0002] Transport climate control systems are typically used to control the environmental condition(s) (e.g., temperature, humidity, air quality, etc.) within a climate-controlled space of a transport unit (e.g., a truck, a container (e.g., a container on a flatbed, an intermodal container, etc.), a van, a semi-trailer, a bus, or other similar transport unit). A transport climate control system may include, for example, a transport refrigeration system (TRS) and / or a heating, ventilation, and air conditioning (HVAC) system. The TRS may control the environmental condition(s) within the climate-controlled space to preserve cargo (e.g., agricultural products, frozen foods, pharmaceuticals, etc.). The HVAC system may control the environmental condition(s) within the climate-controlled space to provide passenger comfort for passengers riding in the transport unit. In some transport units, the transport climate control system may be mounted externally (e.g., on the top of the transport unit, on the front wall of the transport unit, etc.).

[0003] A transport climate control system may include a climate control loop having a compressor, a condenser, an expansion valve, and an evaporator. The working fluid may include a refrigerant that may be compressed and expanded as it flows through the climate control loop and may be used to heat and / or cool a particular space. Summary of the Invention

[0004] Embodiments described herein generally relate to feedthrough protection and overcurrent protection for hermetic compressors used in Transport Climate Control Systems (TCCS).

[0005] In particular, embodiments described herein may prevent melting of sealed electrical feedthroughs of a sealed compressor in a TCCS.

[0006] The transport unit may have a climate-controlled space for cargo or passengers, where the climate-controlled space is climate-controlled (e.g., for controlling temperature, humidity, atmosphere, etc.) by a climate control loop of a transport climate control system. The climate control loop may utilize a working fluid and may include a sealed compressor for compressing the working fluid. The sealed compressor may include a sealed electrical feedthrough for powering a motor of the sealed compressor. It may be desirable to minimize operations that could cause the sealed electrical feedthrough to melt in order to prevent rupture (e.g., bursting, etc.) of the potting of the sealed electrical feedthrough.

[0007] The disclosed embodiments can operate the TCCS to minimize operation under conditions that could cause sufficient heating of the potting body of the sealed electrical feedthrough to melt. The disclosed embodiments can, for example, adjust the operation of the TCCS to halt operation of the sealed electrical feedthrough under conditions that could cause sufficient heating to melt the sealed electrical feedthrough. The disclosed embodiments can, for example, further open the EEV and / or interrupt the flow of power through the sealed electrical feedthrough.

[0008] In one embodiment, a method for feedthrough protection and overcurrent protection of a hermetic compressor used in a TCCS that provides climate control within a climate-controlled space of a transport unit is provided. The TCCS includes a climate control circuit having a hermetic compressor. The hermetic compressor includes a housing and an electric motor located within the housing. The method includes operating the hermetic compressor by providing power to the electric motor of the hermetic compressor via a hermetic electrical feedthrough within the housing of the hermetic compressor to compress a working fluid. The method also includes detecting an operating parameter of the hermetic electrical feedthrough. The method also includes determining whether the hermetic electrical feedthrough is in a melted condition based on the detected operating parameter. In addition, the method includes adjusting the operation of the climate control circuit until the hermetic electrical feedthrough is no longer in the melted condition when it is determined that the hermetic electrical feedthrough is in the melted condition.

[0009] In one embodiment, detecting the operating parameter includes detecting the amperage of the power supplied to the sealed electrical feedthrough. Furthermore, determining whether the sealed electrical feedthrough is in a melting condition includes comparing the detected amperage of the power to a predetermined amperage consumption limit. A "melting" condition is an operating condition of the sealed electrical feedthrough that may cause or result in melting of the sealed electrical feedthrough. For example, a sealed electrical feedthrough in a "melting" condition may indicate that the sealed electrical feedthrough is moving toward and / or is in danger of reaching a condition that causes heating and melting of the sealed electrical feedthrough.

[0010] In one embodiment, providing power to the motor includes providing power from a power source of the TCCS to the sealed electrical feedthrough via an electrical circuit breaker. Additionally, adjusting operation of the climate control circuit includes opening the electrical circuit breaker to interrupt power from the power source to the sealed electrical feedthrough.

[0011] In one embodiment, providing power from the power source to the sealed electrical feedthrough via the electrical circuit breaker includes converting power provided from the power source from direct current to alternating current via an inverter.

[0012] In one embodiment, providing power to the electric motor via the sealed electrical feedthrough includes providing power from a power source of the TCCS to the sealed electrical feedthrough via a contactor. Furthermore, detecting an operating parameter of the sealed electrical feedthrough includes detecting a position state of the contactor, the position state of the contactor corresponding to a current intensity of the power provided through the sealed electrical feedthrough.

[0013] In one embodiment, detecting the operating parameter includes detecting a suction pressure of the hermetic compressor. Additionally, determining whether the hermetic electrical feedthrough is in a melted condition includes comparing the detected suction pressure to a predetermined suction pressure threshold.

[0014] In one embodiment, when the suction pressure of the hermetic compressor is below a predetermined suction pressure threshold, the interior space of the housing along the hermetic electrical feedthrough is below atmospheric pressure.

[0015] In one embodiment, adjusting the operation of the climate control loop includes further opening an Electronic Expansion Valve (EEV) of the climate control loop.

[0016] In one embodiment, further opening of the EEV reduces the conditioning provided by the climate control loop to the climate controlled space of the transport unit.

[0017] In one embodiment, the method further includes operating a climate control circuit to provide conditioning for the climate-controlled space of the transport unit based on a temperature set point for the climate-controlled space. Operating the climate control circuit to provide conditioning includes operating a hermetic compressor to compress a working fluid and adjusting an electronic expansion valve (EEV) of the climate control circuit to a first valve position based on the temperature of the working fluid. Furthermore, adjusting operation of the climate control circuit includes further opening the EEV to a second valve position different from the first valve position.

[0018] In one embodiment, the operating parameters of the electrical feedthrough are not used in the startup sequence of the hermetic compressor.

[0019] In one embodiment, the working fluid comprises a flammable refrigerant.

[0020] In one embodiment, the hermetic compressor is at least one of a hermetic compressor and a semi-hermetic compressor.

[0021] In one embodiment, a TCCS for providing climate control within a climate-controlled space of a transport unit is provided. The TCCS includes a climate control circuit. The climate control circuit includes a sealed compressor for compressing a working fluid. The sealed compressor includes a housing, an electric motor within the housing, and a sealed electrical feedthrough within the housing. The climate control circuit also includes a condenser for cooling the working fluid, an expansion valve for expanding the working fluid, and an evaporator for heating the working fluid. The TCCS also includes a power supply and a climate controller. The climate controller is configured to operate the climate control circuit to provide conditioning to the climate-controlled space of the transport unit, the conditioning including providing power from the power supply to the electric motor via the sealed electrical feedthrough. The climate controller is further configured to detect an operating parameter of the sealed electrical feedthrough, determine whether the sealed electrical feedthrough is in a melted condition based on the detected operating parameter, and when the sealed electrical feedthrough is in the melted condition, adjust the operation of the climate control circuit until the sealed electrical feedthrough is no longer in the melted condition.

[0022] In one embodiment, the climate controller is further configured to detect the amperage of the electrical power passing through the sealed electrical feedthrough to detect an operating parameter of the sealed electrical feedthrough, and to determine that the sealed electrical feedthrough is in a melted condition based on comparing the detected amperage of the electrical power to a predetermined amperage draw limit.

[0023] In one embodiment, the TCCS further comprises an electrical circuit breaker electrically connecting the power supply to the sealed electrical feedthrough. The climate controller is configured to open the electrical circuit breaker to interrupt power provided to the motor via the sealed electrical feedthrough, so as to adjust operation of the climate control circuit such that the sealed electrical feedthrough is no longer in a melted condition.

[0024] In one embodiment, the TCCS further includes a contactor electrically connecting the power supply to the sealed electrical feedthrough. Furthermore, the climate controller is configured to detect a position state of the contactor to detect one or more operating parameters of the sealed electrical feedthrough, the position state of the contactor corresponding to a current level of the power supplied through the sealed electrical feedthrough.

[0025] In one embodiment, the climate controller is further configured to detect a suction pressure of the hermetic compressor to detect an operating parameter, and to determine that the hermetic electrical feedthrough is in a melted condition based on comparing the detected suction pressure to a predetermined suction pressure threshold.

[0026] In one embodiment, the expansion valve is an electronic expansion valve (EEV), and the climate controller is configured to further open the EEV to adjust operation of the climate control circuit such that the sealed electrical feedthrough is no longer in a melted condition.

[0027] In one embodiment, the hermetic compressor is a hermetic compressor or a semi-hermetic compressor. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The described and other features, aspects, and advantages of the transportation climate control system and method of operating the climate control system will be better understood with reference to the following drawings.

[0029] Figure 1 is a perspective view of an embodiment of a climate controlled transport unit attached to a trailer.

[0030] Figure 2 is a schematic diagram of a transportation climate control system according to one embodiment.

[0031] Figure 3A is a schematic cross-sectional view of a sealed electrical feedthrough of a compressor according to one embodiment.

[0032] Figure 3B According to one embodiment Figure 3A Front view of the sealed electrical feedthrough in FIG.

[0033] Figure 4 is a flow chart of a method of controlling a transportation climate control system according to one embodiment.

[0034] Like reference numerals refer to like features. DETAILED DESCRIPTION

[0035] Embodiments described herein generally relate to feedthrough protection and overcurrent protection for hermetic compressors used in transportation climate control systems (TCCS).

[0036] In particular, embodiments described herein may prevent melting of sealed electrical feedthroughs of compressors in TCCSs.

[0037] In the following detailed description, reference is made to the accompanying drawings, which illustrate embodiments in which the present invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice what is claimed, and it should be understood that other embodiments may be utilized without departing from the spirit and scope of the claims. Therefore, the following detailed description and drawings should not be considered limiting.

[0038] Different types of items / cargo may need to be stored under (one or more) specific environmental conditions when stored in a transport unit. For example, perishable items may need to be stored within a specific temperature range to prevent spoilage, while liquid items may need to be kept at a temperature above their freezing point. In addition, items with electronic components may need to be kept in an environmental condition with a low moisture content to avoid damage to their electronic components. Passengers riding in a transport unit may need to be kept in a climate-controlled space with (one or more) specific environmental conditions to ensure their comfort during the ride. For example, the climate-controlled space that accommodates passengers should be at a temperature that is generally comfortable for the passengers. The transport climate control system can blow conditioned air into the climate-controlled space of the transport unit to keep the air in the climate-controlled space at the desired environmental conditions.

[0039] A TCCS can include a climate control system having a compressor for compressing a working fluid containing a refrigerant. The compressor can be a sealed compressor, such as a hermetic or semi-hermetic compressor, and the compressor contains an electric motor within the compressor's sealed housing. For example, a sealed compressor can help prevent leakage of the working fluid. A hermetic compressor has a housing that is configured to be permanently sealed (e.g., the housing is sealed by a complete weld, etc.). A semi-hermetic compressor has a housing that is configured to be sealed for operation, but still openable for maintenance, cleaning, etc. (e.g., the housing is sealed with seals and removable bolts, etc.). A hermetic compressor includes a sealed electrical feedthrough in its sealed housing for providing power to the electric motor. However, various operations of the compressor can cause the sealed electrical feedthrough to heat to a temperature that can cause it to melt and ultimately fail structurally (e.g., rupture, etc.). This can allow, for example, refrigerant in the working fluid to leak into the surrounding environment, causing the surrounding environment to become hazardous (e.g., leaking flammable refrigerant can make the surrounding environment flammable).

[0040] Embodiments described herein generally relate to limiting operations that could cause a sealed electrical feedthrough to melt in a compressor in a transportation climate control system (TCCS). The transportation climate control system includes a climate control loop having a compressor for compressing a working fluid. The climate control loop is configured to provide conditioning (for example, for controlling temperature, humidity, atmosphere, etc.) to a climate-controlled space. The TCCS includes a climate controller for controlling the climate control loop. For example, the climate controller can be configured to adjust the operation of the climate control loop to minimize operations that could cause heating and melting of the sealed electrical feedthrough. This can advantageously prevent weakening and accidental rupture of the sealed electrical feedthrough.

[0041] Figure 1One embodiment of a climate controlled transport unit 1 is illustrated attached to a trailer 5. The climate controlled transport unit 1 comprises a transport unit 10 and a transport climate control system (TCCS) 20 for the transport unit 10. Figure 1 Dashed lines are used to illustrate features that are not visible in the illustrated view. The transport unit 10 can be attached to a trailer 5 that is configured to tow the transport unit 10 to and from various locations. When not being transported, the transport unit 10 can be parked and detached from the trailer 5. It should be understood that the embodiments described herein are not limited to trailer and trailer units, but can be applied to any type of transport unit, such as a container (e.g., a container on a flatbed, an intermodal container, etc.), a truck, a van, a commercial bus (e.g., a school bus, a rail car, a subway car, etc.), or other similar transport units.

[0042] The TCCS 20 includes a climate control unit (CCU) 30 that provides environmental control (e.g., temperature, humidity, air quality, etc.) within the climate-controlled space 12 of the transport unit 10. The climate-controlled space 12 is the interior space of the transport unit 10. The CCU 30 provides conditioned air to the climate-controlled space 12 of the transport unit 10 to provide a desired conditioned environment for items stored in the climate-controlled space 12 of the transport unit 10. The desired conditioned environment of the climate-controlled space 12 may have one or more desired environmental conditions (e.g., temperature, humidity, air quality, etc.). For example, when perishable items are stored in the transport unit 10, the CCU 30 may provide cooled air to the climate-controlled space 12. In another example, when electronic equipment is in the transport unit 10, the CCU 30 may dehumidify the air in the climate-controlled space 12 of the transport unit 10. The CCU 30 includes a climate control loop (e.g., see Figure 2 etc.), for providing conditioned air to the climate-controlled space 12.

[0043] The CCU 30 is disposed on the front wall 14 of the transport unit 10. In other embodiments, it should be understood that the CCU 30 can be disposed, for example, on the roof 14 or another wall of the transport unit 10. The climate-controlled transport unit 10 can include a battery (not shown), an internal combustion engine (not shown), or both as a power source. The TCCS 20 can be a hybrid system that uses a combination of battery power and engine power, or it can be an electric system that does not include or rely on the TCCS 20 or the internal combustion engine of the trailer 5 for power.

[0044] The TCCS 20 also includes a programmable climate controller 40 and one or more sensors 50. The sensors 50 are configured to measure one or more parameters of the climate-controlled transport unit 1 (e.g., ambient temperature and / or ambient humidity outside the transport unit 10, compressor suction pressure, compressor discharge pressure, the temperature of the air provided by the CCU 30 to the climate-controlled space 12, the temperature of the air returned from the climate-controlled space 12 to the CCU 30, the humidity within the climate-controlled space 12, etc.) and communicate the parameter data to the climate controller 40. The climate controller 40 is configured to control the operation of the TCCS 20, including components of the climate control loop. The climate controller 40 can be a single integrated control unit 42 or a control unit formed by a distributed network of climate controller elements 42, 44. The number of distributed control elements in a given network can depend on the specific application of the principles described herein.

[0045] Figure 2 is a schematic diagram of an embodiment of a TCCS 100. The TCCS may be a TCCS of a climate controlled transport unit (e.g., Figure 1 TCCS 20 in the transport unit, etc.). The TCCS includes a climate control loop 105. The climate control loop 105 can be used to control the climate controlled space of the transport unit (e.g., Figure 1 (One or more) environmental conditions (for controlling, for example, temperature, humidity, atmosphere, etc.) of the climate-controlled space 12 of the transport unit 10, etc.

[0046] The climate control loop 105 includes a compressor 110, a condenser 130, an expansion valve 140, and an evaporator 150. In one embodiment, the climate control loop 105 can be modified to include additional components, such as one or more additional valves, sensors, distributors, accumulator tanks, filter driers, receiving tanks, overflow tanks, etc. In one embodiment, the climate control loop 105 can be arranged in the CCU of the TCCS 100 (e.g., in Figure 1 in CCU 30, etc.).

[0047] The operation of the climate control loop 105 is controlled by a programmable climate controller 180. The climate controller 180 is configured to detect various operating parameters of the climate control loop 105. For example, the climate controller 180 may use one or more sensors (e.g., Figure 1 The climate controller 180 includes sensors 50, current sensor 182, suction pressure sensor 184, etc., for detecting one or more operating parameters of the TCCS 100 and the climate control loop 105 of the TCCS 100. In one embodiment, the climate controller 180 includes a processor (not shown) and a memory (not shown) for storing information. The climate controller 180 is configured to control the operation of the TCCS 100 and its components. Figure 2However, it should be understood that the climate controller 180 of the embodiment can be a single integrated control unit or a distributed network of climate controller elements (e.g., Figure 1 a distributed network of climate controller elements 42, 44, etc.).

[0048] The components of the climate control circuit 105 are fluidly connected. For clarity, Figure 2 Dotted lines are provided to indicate fluid flow through different components (e.g., compressor 110, condenser 130, evaporator 150), and the dotted lines should be understood as not specifying a specific route within each component. Figure 2 and Figure 4 Dashed lines are provided to indicate optional features in some embodiments. Figure 2 The dashed lines are provided to illustrate electronic communication between different components. For example, the dashed line extends from the climate controller 180 to the inverter 168 because the climate controller 180 is configured to control the inverter 168. Figure 2 3 , short dashed lines are provided to indicate power flow between components. For example, power source 162 provides power to inverter 168 .

[0049] A working fluid flows through the climate control circuit 105. The working fluid includes a refrigerant. The refrigerant in the working fluid can be a non-flammable refrigerant or a flammable refrigerant. For example, a flammable refrigerant can be a single refrigerant or a refrigerant mixture (e.g., a combination of two or more refrigerants) classified as A2L–B3 according to ASHRAE Standard 34 (e.g., ASHRAE Standard 34-2019). For example, a non-flammable refrigerant can be a single refrigerant or a refrigerant mixture classified as A1 or B1 according to ASHRAE Standard 34. In one embodiment, the working fluid includes at least one flammable refrigerant. In one embodiment, the refrigerant of the working fluid includes one or more refrigerants classified as A2L. For example, the refrigerant can be a single refrigerant or a refrigerant mixture classified as an A2L refrigerant according to ASHRAE Standard 34. It should be noted that the working fluid can also include non-refrigerant components. For example, non-refrigerant components can be, but are not limited to, lubricants, impurities, refrigeration system additives, tracers, ultraviolet dyes, and solubilizers. Generally, these additional components are present in low concentrations relative to the refrigerant in the working fluid.

[0050] In one embodiment, the climate control loop 105 is configured to operate in a cooling mode to provide conditioned air (e.g., cooled air) to the climate-controlled space. The following describes the flow of the working fluid through the climate control loop 105 in the cooling mode during normal operation (e.g., without conditioning to prevent the sealed electrical feedthrough 118 from being in a melted condition, etc.). Generally, when operating in the cooling mode, the flow path of the working fluid in the climate control loop 105 is from the compressor 110 to the condenser 130, from the condenser 130 to the expansion valve 140, from the expansion valve 140 to the evaporator 150, and from the evaporator 150 back to the compressor 110.

[0051] Starting with compressor 110, compressor 110 includes a housing 112 having an intake port 114, an exhaust port 116, and a sealed electrical feedthrough 118. Compressor 110 is a sealed compressor, wherein housing 112 is a sealed housing. In one embodiment, sealed compressor 110 is a hermetic compressor or a semi-hermetic compressor. Compressor 110 includes a motor 120 and a compression mechanism (not shown) (e.g., one or more rotatable / orbitable scroll(s), piston(s), screw(s), etc.) arranged within the sealed housing 112 of compressor 110. Housing 112 is configured to fluidly seal the internal components of compressor 110 (e.g., motor 120, compression mechanism of compressor 110, etc.) from the external environment (e.g., outside air, etc.) while allowing working fluid to flow into / out of housing 112 (e.g., through intake port 114, exhaust port 116, etc.). For example, except for the ports of housing 112 for climate control circuit 105 (e.g., intake port 114, exhaust port 116, etc.), housing 112 is fluid-tight. When supplied with electrical power, electric motor 120 converts the electrical power into mechanical energy that drives a compression mechanism and compresses the working fluid. Electrical power is supplied through sealed housing 112 via sealed electrical feedthrough 118 within sealed housing 112. Sealed electrical feedthrough 118 is discussed in more detail below.

[0052] A working fluid in a low-pressure gaseous state or a mostly gaseous state is drawn into the compressor 110 through the suction port 114 of the compressor 110. The working fluid is compressed as it flows through the compressor 110. Operation of the motor 120 causes the working fluid to be compressed (e.g., the operation of the motor 120 drives a compression mechanism to compress the working fluid, etc.). The compressed working fluid is discharged from the compressor 110 through the discharge port 116 of the compressor 110 and flows to the condenser 130.

[0053] As the compressed working fluid passes through condenser 130, condenser 130 cools the compressed working fluid. A first process fluid PF1 flows through condenser 130 to be separated from the working fluid. The first process fluid PF1 may be ambient air (e.g., from Figure 1 The condenser 130 is a heat exchanger that allows the working fluid and the first process fluid PF1 to enter into a heat transfer relationship without physical mixing as they each flow through the condenser 130. As the working fluid flows through the condenser 130, the first process fluid PF1 absorbs heat from the working fluid and cools the working fluid. As the working fluid flows through the condenser 130, it is cooled by the condenser 130 and becomes a liquid, or mostly a liquid. The cooled working fluid flows from the condenser 130 to the expansion valve 140.

[0054] When the cooled working fluid from condenser 130 flows through expansion valve 140, expansion valve 140 expands the cooled working fluid from condenser 130. This expansion causes the temperature of the working fluid to decrease. The expanded working fluid is in a two-phase gas / liquid state. The expanded gaseous / liquid working fluid flows from expansion valve 140 to evaporator 150. In one embodiment, expansion valve 140 is an electronic expansion valve (EEV) having an opening that can be adjusted to vary the amount of working fluid flowing through expansion valve 140. During normal operation (e.g., providing regulation without adjusting the melting condition of sealed electrical feedthrough 118), climate controller 180 can be configured to control the opening of EEV 140 based on the superheat of the working fluid after passing through evaporator 150. For example, climate controller 180 can be configured to control the opening of EEV 140 (e.g., select an open valve position of EEV 140) so that the temperature T1 of the heated working fluid is at or approximately within a target temperature / range. The target temperature / range may correspond to a predetermined amount / range of superheat.

[0055] When the expanded working fluid flows through the evaporator 150, the evaporator 150 heats the expanded working fluid. Figure 2As shown, a second process fluid PF2, separate from the working fluid, conditions (e.g., cools, heats, etc.) the climate-controlled space. For example, the second process fluid PF2 may be air from the climate-controlled space, which is circulated through evaporator 150 and returned to the climate-controlled space to cool the space. The second process fluid PF2 may be an intermediate fluid (e.g., a solution comprising water, ethylene glycol, etc.) that is used to condition the air in the climate-controlled space. Evaporator 150 is a heat exchanger that allows the working fluid and the second process fluid PF2 to be in a heat transfer relationship without physically mixing as they each flow through evaporator 150. As the working fluid flows through evaporator 150, it absorbs heat from the air and cools the second process fluid PF2. As the working fluid flows through evaporator 150, it is heated by evaporator 150 and becomes a gaseous state, or a majority of it. The heated working fluid flows from evaporator 150 back to suction port 114 of compressor 110.

[0056] The TCCS 100 includes a power system 160 that provides power to the motor 120 of the compressor 110. The power system 160 may include a power source 162, an inverter 168, and an electrical circuit breaker 170. The power source 164 provides power to power the motor 120 of the compressor 110. For example, the power source 162 may provide power to the motor 120 via at least the electrical circuit breaker 172. In one embodiment, the power provided from the power source 162 may be direct current (DC) power. The power source 164 may provide direct current (DC) power to the inverter 168, which converts the DC power into AC power. In one embodiment, the power source 162 may include a battery 164 that provides power to power the motor 120. In one embodiment, the power source 162 may also include an internal combustion engine 166A and a generator 166B as local power sources. The internal combustion engine 166A and the generator 166B may be provided in the TCCS 100 (e.g., located at Figure 1 30 in the middle) and / or a vehicle pulling a transport unit of the TCCS 100 (e.g., Figure 1 In one embodiment, the internal combustion engine 166A and the generator 166B can be used to charge the battery 164 during transport. For example, the battery 164 is the primary power source for the electric motor 120 of the compressor 110. In other embodiments, the TCCS 100 can be a purely electric system (e.g., without the internal combustion engine 166A) that relies on utility power to charge the battery 164.

[0057] The inverter 168 converts DC power provided from the power source 162 (e.g., from the battery 164) into alternating current (AC) that is provided to the motor 120. The compressor 110 can be a multi-speed compressor, wherein the motor 120 is a variable speed motor. The frequency of the AC provided to the motor 120 controls the speed at which the motor 120 operates. The climate controller 180 is configured to control the speed of the motor 120 by controlling the output frequency of the inverter 168. For example, the controller 180 controls the inverter 168 to control the speed of the motor 120 (e.g., change the speed of the motor 120, etc.). The speed of the compressor 110 can be selected based on the amount of regulation required by the climate control loop 105 (e.g., when there is a higher cooling / heating demand for the climate-controlled space, the climate controller 180 causes the compressor 110 to operate at a higher speed).

[0058] like Figure 2 As shown, power flows through the electrical circuit breaker 172 to the compressor 110. The climate controller 180 is configured to operate the electrical circuit breaker 172 based on the current intensity provided to the compressor 110. The electrical circuit breaker 172 has an on position and an off position. In the on position, power flows from the electrical circuit breaker 172 to the compressor 110. In the off position, the electrical circuit breaker 172 is disconnected so that power (e.g., each current of the power, etc.) does not flow through the electrical circuit breaker 172 (e.g., no power is provided to the compressor 110 or the motor 120 of the compressor 110). The climate controller 180 is configured to control the position of the electrical circuit breaker 172. In one embodiment, the power is multi-phase power, and the electrical circuit breaker 172 in the off position will interrupt the flow of power of all currents of the multi-phase power.

[0059] In one embodiment, the electrical circuit breaker 172 can be a contactor having a contact position POS. For example, the contact position POS is the position of a contact point (not shown) in the contactor. When the current intensity I1 flowing through the contactor changes the contact position POS, the contact position POS corresponds to the current intensity I1 of the power flowing through the contactor. The climate controller 180 can be configured to use the contact position POS to determine the current intensity I1 of the current flowing through the contactor and flowing to the compressor 110. In one embodiment, the climate controller 180 can detect the position state POS by a contactor position state POS signal transmitted from the contactor to the climate controller 180. In one embodiment, the power is multi-phase power, and the contactor has a contact point for each current in the multi-phase power. For example, the climate controller 180 can be configured to detect the contact position and determine the current intensity of each current in the multi-phase power.

[0060] In one embodiment, the climate controller 180 is connected to an HMI 190 and a telematics unit 192. The HMI 190 allows the climate controller 180 to send information to the climate controlled transport unit (e.g., Figure 1 Displays a warning to the operator of the climate controlled transport unit 1, etc. Figure 2 As shown, the TCCS 100 may include an HMI 190. For example, the TCCS 100 (e.g., Figure 1 The CCU of the vehicle (e.g., the CCU 30 in the vehicle) may include the HMI 190. In another embodiment, a vehicle (e.g., Figure 1 The trailer 5 in the vehicle, etc.) may include an HMI 190. The telematics unit 192 allows the climate controller 180 to wirelessly communicate warnings to a remote device (not shown) (eg, a computer, server, server network, etc.).

[0061] In some embodiments, the TCCS 100 may include a current sensor 182 that measures the current intensity I1 of the power supplied to the compressor 110. The climate controller 180 may be configured to detect the current intensity I1 of the power supplied to the compressor 110 through the current sensor 182. The electrical circuit breaker 172 may be a circuit breaker, a switch, a relay, a contactor, etc., operated by the controller 180. The climate controller 180 may be configured to operate the electrical circuit breaker 172 based on the current intensity I1 of the power supplied to the compressor 110. The current sensor 182 measures the power supplied to the compressor 110 by the inverter 168.

[0062] like Figure 2 As shown, current sensor 182 measures power between electrical circuit breaker 172 and compressor 110. In other embodiments, current sensor 182 may be arranged to measure power between inverter 168 and electrical circuit breaker 172. In one embodiment, current sensor 182 may be incorporated into electrical circuit breaker 172 or inverter 168.

[0063] The compressor 110 includes a sealed electrical feedthrough 118 within the housing 112 of the compressor 110. The sealed electrical feedthrough 118 directs electrical power for the electric motor 120 through the housing 112 of the compressor 110 while maintaining a hermetic seal of the compressor 110 (e.g., a hermetic seal of its housing 112, etc.). For example, the working fluid within the compressor 110 cannot pass through the sealed electrical feedthrough 118.

[0064] Figure 3A A schematic cross-sectional view of an electrical feedthrough 118 in a compressor 110 is shown according to one embodiment. Figure 3BA front view of electrical feedthrough 118 is shown according to one embodiment. Sealed electrical feedthrough 118 allows power to pass through housing 112 while maintaining a seal therewith.

[0065] like Figure 3A As shown, sealed electrical feedthrough 118 includes electrical pins 122, a potting body 124, and an outer ring 126. Sealed electrical feedthrough 118 extends through port 113 in housing 112 of compressor 110. Sealed electrical feedthrough 118 fluidically seals port 113, maintaining a hermetic seal between compressor 110 and housing 112 (e.g., preventing gaseous refrigerant, such as a working fluid, from passing through port 113). Outer ring 122 of electrical feedthrough 118 is secured to housing 112 to seal port 113. For example, outer ring 122 may be a metal ring welded to housing 112.

[0066] Each electrical pin 122 extends through the potting body 124 to the sealed interior space 111 of the compressor 110. Each electrical pin 122 provides an electrical conduit through the sealed housing 112. Current for powering the motor 120 flows through the sealed electrical feedthrough 118 via a corresponding one of the electrical pins 12. For example, each pin 122 has a connection to a power source 162 (e.g., via Figure 3A An outer end of the power supply 110 is connected to an electric circuit breaker, etc. in the circuit breaker and an inner end of the power supply 110 is connected to the electric motor 120. Figure 3A and Figure 3B The electrical feedthrough 118 in the embodiment has three electrical pins 122 for conducting each phase of the three-phase AC. However, it should be understood that the electrical feedthrough 118 can have a different number of electrical pins 122 than the three basic configurations of the compressor 110 (e.g., the type of power supply used for the motor 120). In other embodiments, the sealed electrical feedthrough 118 may include one or more electrical pins 122. For example, the electrical feedthrough 118 in one embodiment can have a single electrical pin 122 for providing power to the motor 120 (e.g., a motor configured to utilize DC power or single-phase power, etc.). For example, the electrical feedthrough 118 in one embodiment can include more than three electrical pins 122 (e.g., including one or more additional electrical pins 122 for providing separate power / electrical connections to the compressor 110, etc.).

[0067] The potting body 124 fills and seals the inner space of the outer ring 126. Figure 3BAs shown, a potting body 124 is disposed between the outer ring 126 and each electrical pin 122, and between each electrical pin 122. For example, the potting body 124 can hold each electrical pin 122 in place within the outer ring 126. The potting body 124 forms a seal within the outer ring 126 (e.g., preventing the working fluid, external air, etc. from passing through the outer ring 126). The potting body 124 is an electrically insulating polymer that is solid at room temperature (e.g., a non-conductive polymer, an electrically insulating epoxy resin, etc.). The electrical pins 122 are made of a conductive material (e.g., a metal, a non-metal, etc.).

[0068] The electrically insulating potting body of the sealed electrical feedthrough can melt when heated to its melting point (e.g., heated to the melting point of the electrically insulating polymer). The melting of the potting body (e.g., at least a portion of the potting body melts) will reduce the structural integrity of the potting body. Heating sufficient to melt the potting body will weaken the structural integrity of the sealed electrical feedthrough. The pressure of the compressed working fluid (e.g., the discharge pressure of the compressor, etc.) can cause the weakened sealed electrical feedthrough to rupture (e.g., rupture the seal of the potting body, burst the potting body and / or the electrical pin 122, etc.). The working fluid can then leak from the compressor into its external environment (e.g., into the internal space of the CCU) through the ruptured electrical feedthrough. For example, the ruptured electrical feedthrough allows flammable refrigerant to leak and cause the external environment of the compressor to become a flammable environment.

[0069] In many configurations, a sealed electrical feedthrough is disposed on the suction side of the compressor (e.g., extending into a portion of the interior volume of the sealed housing, upstream of the compressor's compression mechanism, containing pre-compressed working fluid and typically at suction pressure, etc.). When compressor 110 is operated such that the suction pressure on the compressor's suction side is at a vacuum condition, the sealed electrical feedthrough increases charge accumulation at the sealed electrical feedthrough, which increases the likelihood / incidence of arcing at the electrical pin(s) (e.g., between the electrical pins of the sealed electrical feedthrough, from the electrical pins of the sealed electrical feedthrough, etc.). The specific amount of pressure that causes the increased likelihood / incidence of arcing (e.g., how much below atmospheric pressure) can vary based on the compressor configuration. The arc can heat the electrical pin(s), which in turn heats the potting. The arc can heat the potting and cause it to melt (e.g., heating at least a portion of the potting to its melting point). The compressor's discharge pressure can then rupture the weakened sealed electrical feedthrough, similar to that discussed above. For example, improper maintenance, software failures, and / or hardware failures in the refrigeration system may cause discharge pressure to be applied to the suction side of the compressor.

[0070] Various electrical and mechanical issues can cause the motor to draw sufficient amperage to heat and melt the potting. For example, an electrical short and / or a motor / compressor with a locked rotor can cause the motor to draw higher amperage. The higher amperage can cause resistive heating of the electrical pin(s) through the electrical feedthrough, which can heat and melt the potting (e.g., heating at least a portion of the potting to its melting point). The discharge pressure of the compressor can cause the potting to burst.

[0071] Such electrical shorts occur within the compressor. For example, electrical shorts that can cause an increase in current intensity sufficient to heat and melt the potting body can occur at the sealed electrical feedthrough (e.g., arcing at the (one or more) electrical pins, etc.), between the sealed electrical feedthrough and the motor, and / or within the motor (e.g., in the windings of the motor, etc.). As the compressor wears, metal particles are generated in the working fluid. The metal particles can adhere to the inner surface of the compressor, including the (one or more) electrical pins of the electrical feedthrough, as they move. The accumulation of metal particles on the electrical feedthrough and the (one or more) electrical pins of the electrical feedthrough can destroy the dielectric properties of the (one or more) electrical pins that prevent arcing. For example, the accumulation of metal particles can form a conductive path between the pins, which can cause an electrical short.

[0072] A locked rotor in the motor / compressor can be caused by, for example, a torque on the motor exceeding its maximum torque, a phase loss in the multi-phase power supply provided to the motor, and / or a mechanical fault in the motor (e.g., a mechanical seizer of the compressor, bearing failure, interference issues, etc.).

[0073] The TCCS 100 is configured to prevent melting of the potting body 124 of the sealed electrical feedthrough 118. The climate controller 180 can be configured to operate the TCCS 100 to limit operation of the sealed electrical feedthrough 118 under melting conditions that could cause the potting body 124 of the sealed electrical feedthrough 118 to melt. A "melting" condition is an operating condition of the sealed electrical feedthrough (e.g., the sealed electrical feedthrough is operated under a condition) that could cause or result in the potting body 124 being heated to a temperature that melts the potting body 124 (e.g., a condition that occurs before the potting body 124 reaches the melting temperature of the potting body 124, etc.). For example, a sealed electrical feedthrough in a "melting" condition can indicate that the sealed electrical feedthrough is moving toward and / or is in danger of reaching a condition that could cause the sealed electrical feedthrough to heat and melt. For example, climate controller 180 can operate climate control circuit 105 to minimize operation under conditions that increase the likelihood of arcing at sealed electrical feedthrough 118 (e.g., at electrical pin 112) and / or provide a current intensity I1 through sealed electrical feedthrough 118 that can cause heating of potting body 124 sufficient to melt sealed electrical feedthrough 118. For example, sealed electrical feedthrough 118 is in a melting condition when operating sealed electrical feedthrough 118 under a pressure that can cause arcing at sealed electrical feedthrough 118 sufficient to heat and melt potting body 124, and / or when the current intensity I1 through sealed electrical feedthrough 118 is sufficient to cause heating and melting of potting body 124.

[0074] In one embodiment, climate controller 180 is configured to determine whether sealed electrical feedthrough 118 is in a melted condition based on one or more detected operating parameters. The one or more detected operating parameters may include one or more of a suction pressure P1 of compressor 110 and an amperage I1 of electrical power flowing through sealed electrical feedthrough 118. For example, climate controller 180 may compare the detected suction pressure P1 to a predetermined suction pressure threshold and / or compare the detected amperage I1 to a predetermined amperage draw limit. In one embodiment, sealed electrical feedthrough 118 is in a melted condition when the detected suction pressure P1 is less than the predetermined suction pressure threshold, or when the detected amperage I1 exceeds the predetermined amperage draw limit.

[0075] For example, the predetermined current draw limit can be a limit based on the normal current draw of the motor 120 (e.g., the current draw of the motor 120 without any electrical shorts or locked rotors, not during a normal startup cycle of the motor 120, etc.). The predetermined current draw limit can be a value determined based on previous testing (e.g., based on compressors 110, motors 120, climate control circuits 105, motor / compressor / climate control circuits of the same or similar configurations). In one embodiment, the predetermined current draw limit is below the minimum current that can cause sufficient heating of the potting body 124 to melt the sealed electrical feedthrough 118.

[0076] For example, when the suction pressure P1 of the compressor 110 is below a predetermined suction pressure threshold, the interior space 111 of the housing 112 having the sealed electrical feedthrough 118 has a pressure below atmospheric pressure (e.g., the inner end(s) of the pin(s) 122 of the sealed electrical feedthrough 118 are under vacuum, etc.). The predetermined suction pressure threshold may be a value determined based on previous testing of negative pressure (e.g., based on testing of compressors, motors / compressors / working fluids / refrigerants / climate control circuits of the same or similar configurations) that caused an arc to form along / between the electrical pin(s) 122 of the sealed electrical feedthrough 118. In one embodiment, the suction pressure P1 and the pressure of the interior space of the housing 112 into which the sealed electrical feedthrough 118 extends (e.g., the pressure of the interior space 111) may be the same or substantially the same.

[0077] The climate controller 180 can be configured to detect each of one or more operating parameters to determine whether the sealed electrical feedthrough 118 is in a melt condition. For example, the climate controller 180 can be configured to detect the suction pressure P1 of the compressor 110 using the suction pressure sensor 184 of the climate control circuit 105. The suction pressure sensor 184 can be disposed in the climate control circuit 105 between the evaporator 150 and the compressor 110 (e.g., downstream of the evaporator 150 and upstream of the suction port 114 of the compressor 110). For example, the climate controller 180 can be configured to detect the current intensity I1 of the power passing through the sealed electrical feedthrough 118 using the contact position POS of the contactor. For example, the climate controller 180 can be configured to detect the current intensity I1 of the power passing through the sealed electrical feedthrough 118 using the current sensor 182. In one embodiment, the power provided to the motor 120 can be multi-phase AC power. In such an embodiment, the climate controller 180 can be configured to detect the current intensity of each phase of the multi-phase AC power (e.g., the current intensity of the first phase / first current, the current intensity of the second phase / second current, and the current intensity of the third phase / third current). For example, the contactor can have a contact point for each phase, and the climate controller 180 is configured to detect the corresponding contact position POS of the contactor for each phase.

[0078] In one embodiment, climate controller 180 is configured to adjust the operation of climate control circuit 105 so that sealed electrical feedthrough 118 is not in a melted condition. For example, when sealed electrical feedthrough 118 is in a melted condition, climate controller 180 adjusts the operation of climate control circuit 105 so that sealed electrical feedthrough 118 is no longer in a melted condition. In one embodiment, the adjustment of climate control circuit 105 may include further opening EEV 140 (e.g., adjusting the opening of EEV 140 to allow more working fluid to flow through EEV 140) and / or interrupting the flow of power to electric motor 120. For example, climate controller 180 may be configured to open electrical circuit breaker 172 (e.g., open a contactor, etc.) to interrupt the flow of power through sealed electrical feedthrough 118 for electric motor 120.

[0079] Figure 4 is a flow chart of a method 1000 of controlling a TCCS that provides climate control within a climate controlled space of a transport unit. In one embodiment, as described above, the method may be applied to control Figure 1 In one embodiment, as described above, the method 100 may be applied to control a TCCS 20 (e.g., employed by a climate controller 40, etc.). Figure 210. The method 1000 may be implemented by the TCCS 100 (eg, as employed by the climate controller 180, etc.).

[0080] At 1010, the TCCS operates a climate control loop (e.g., climate control loop 105) to regulate a climate-controlled space (e.g., climate-controlled space 12). In one embodiment, the climate-controlled space is a climate-controlled space of a transport unit (e.g., climate-controlled space 12 of transport unit 10). The climate control loop includes a sealed compressor (e.g., compressor 110), a condenser (e.g., condenser 130), an expansion valve (e.g., expansion valve 140), and an evaporator (e.g., evaporator 150). The compressor includes a sealed housing (e.g., housing 112), a motor (e.g., motor 120) disposed within the sealed housing, and a sealed electrical feedthrough (e.g., sealed electrical feedthrough 118) extending through the housing. For example, electricity for powering the motor is provided through the sealed housing via a sealed electrical feedthrough in the sealed housing. The sealed electrical feedthrough extends through the sealed housing and is electrically connected to the motor.

[0081] A working fluid (e.g., the working fluid of climate control loop 105) flows through the climate control loop. The compressor compresses the working fluid, the condenser cools the working fluid, the expansion valve expands the working fluid, and the evaporator heats the working fluid. The climate controller operates the climate control loop to provide climate control (e.g., for controlling temperature, humidity, atmosphere, etc.) within the climate-controlled space based on a temperature set point for the climate-controlled space. For example, the climate control loop can operate in a cooling mode to provide conditioned air (e.g., cooled air, etc.) to the climate-controlled space, such that the climate-controlled space is cooled to or near the temperature set point.

[0082] Operating the climate control loop to condition the climate-controlled space at 1010 includes operating a compressor to compress a working fluid at 1012. Operating the compressor to compress the working fluid at 1012 includes providing power to the compressor's electric motor via a sealed electrical feedthrough of the compressor. The TCCS includes an electrical system (e.g., electrical system 160) having a power source (e.g., power source 162) for providing power to power the compressor's electric motor. For example, the power source can include a battery (e.g., battery 164) as a primary energy source. Alternatively, the power source can include a local power generation device (e.g., internal combustion engine 166A, generator 166B, etc.) for charging the battery during transportation.

[0083] In one embodiment, providing power to the motor of the compressor via the sealed electrical feedthrough at 1012 may include providing power from the power source to the sealed electrical feedthrough via an electrical circuit breaker (e.g., electrical circuit breaker 172) at 1014. When power flows from the power source to the sealed electrical feedthrough, the power flows through the electrical circuit breaker. In some embodiments, the power provided by the power source is DC power (e.g., DC power provided by a battery), and an inverter (e.g., inverter 168) converts the power from DC power to AC power. The inverter can electrically connect the power source to the electrical circuit breaker. In such an embodiment, providing power from the power source to the sealed electrical feedthrough via the electrical circuit breaker at 1014 may include the inverter inverting the power from DC power to AC power. In one embodiment, the climate controller can be configured to control the output frequency of the inverter to control the speed of the compressor. For example, the speed of the compressor can be controlled / selected based on the amount of adjustment required for the climate-controlled space.

[0084] In one embodiment, the expansion valve is an electronic expansion valve (EEV) that is controlled by a climate controller to adjust the flow rate of the working fluid through the EEV. Operating the climate control loop to adjust the climate-controlled space at 1010 may include, at 1016, the climate controller operating the EEV to expand the working fluid. For example, operating the EEV at 1016 may include the climate controller adjusting the EEV (e.g., a valve position of the EEV) based on the temperature of the working fluid after being heated by the evaporator (e.g., temperature T1). For example, the climate controller may be configured to maintain the superheat of the heated working fluid at or approximately within a predetermined amount or range (e.g., configured to maintain the temperature of the heated working fluid at or approximately within an amount or range corresponding to a predetermined amount or range of superheat, etc.). For example, the climate controller may adjust the EEV to a first valve position based on the temperature of the heated working fluid (e.g., the EEV being in the first valve position causes the temperature of the heated working fluid to be at an amount / range corresponding to a predetermined amount / range of superheat, etc.). Method 1000 then proceeds from 1010 to 1030 , or alternatively proceeds to 1020 first.

[0085] At optional 1020, the climate controller may determine whether the compressor is in its startup sequence. A compressor may operate in various ways during its startup. For example, a large current ("inrush current") may be drawn by the compressor's motor during the compressor's startup sequence (e.g., a large amperage during compressor startup, etc.). In one embodiment, the climate controller may determine whether the compressor is in its startup sequence based on the amount of time since the compressor's motor was started (e.g., the amount of time since current was first supplied to the motor). The climate controller may determine that the compressor is not in its startup sequence when the motor's startup period has elapsed. The climate controller may determine that the compressor is not in its startup sequence when the amount of time elapsed since the motor was started is greater than the startup period (e.g., the compressor is not in a startup state after the startup period has elapsed since current was initially supplied to the motor to start it, etc.). The startup period may be a predetermined amount of time based on, for example, the amount of time typically required for the compressor to complete startup (e.g., the normal amount of time required to reach steady-state operation, complete a startup sequence, etc.).

[0086] In one embodiment, the climate controller can be configured to determine that the compressor is in a compressor startup sequence at 1020 by comparing the detected current supplied to the electric motor with an expected inrush current. The expected consumption limit can be a value determined based on previous testing (e.g., based on the same or similar configurations of the compressor 110, motor 120, climate control circuit 105, motor / compressor / climate control circuit, etc.). For example, when the detected current supplied to the electric motor exceeds the expected inrush current by more than a predetermined threshold, the climate controller can be configured to determine that the compressor is not in a compressor startup sequence at 1020. The detected current exceeding the expected inrush current by a predetermined threshold can indicate, for example, a compressor fault (e.g., locked rotor, electrical short, etc.), rather than simply indicating that the compressor is in a startup sequence.

[0087] At optional 1020, if the climate controller determines that the compressor is in a startup sequence (e.g., less than the compressor startup period, less than a predetermined amount of time has elapsed since the motor was started, the current provided to the motor is an expected inrush current or less than the expected inrush current, etc.), method 1000 returns to optional 1020. In one embodiment, the climate controller can be configured to delay for a specific amount of time before returning to optional 1020. At optional 1020, if the climate controller determines that the compressor is not in a startup sequence (e.g., in steady state, the time since the starter motor began to start is equal to or greater than a predetermined amount of time, the compressor startup period has elapsed, etc.), method 1000 continues to 1030. Thus, in one embodiment, the actions performed after optional 1020 (e.g., at 1030, 1040, 1060, 1061, etc.) can occur after the compressor startup sequence. For example, the operating parameters detected at 1030 are not for the compressor startup sequence and / or are not during the compressor startup sequence (e.g., do not correspond to a normal inrush current for starting the motor, etc.). In one embodiment, method 1000 may not include optional 1020. In such an embodiment, method 1000 may proceed directly from 1010 to 1030.

[0088] At 1030, the climate controller detects one or more operating parameters of the sealed electrical feedthrough. In some embodiments, the detected operating parameter(s) of the sealed electrical feedthrough may include a suction pressure of the compressor (e.g., suction pressure P1) and / or an amperage of the electrical power passing through the sealed electrical feedthrough (e.g., amperage I1).

[0089] In one embodiment, detecting one or more operating parameters of the sealed electrical feedthrough at 1030 may include detecting a suction pressure of the compressor at 1032. The climate controller may be configured to detect the suction pressure of the compressor at 1032 via a pressure sensor of the climate control loop (e.g., pressure sensor 186).

[0090] In one embodiment, at 1030, detecting one or more operating parameters of the sealed electrical feedthrough may include detecting the amperage of the power provided to the sealed electrical feedthrough 1034. In one embodiment, the climate controller may be configured to detect the amperage of the power using a current sensor (e.g., current sensor 182). In one embodiment, as described above, power is provided to the sealed electrical feedthrough via an electrical circuit breaker. In such an embodiment, the electrical circuit breaker may be a contactor. The climate controller may be configured to detect the amperage of the power via the contactor. As described above, the contact position of the contact point (e.g., contact position POS) corresponds to the amperage of the power because the contact position varies with the amperage of the power flowing through the contactor. For example, the climate controller may be configured to detect the amperage of the power by detecting the contact position of the contactor (e.g., contact position POS). Method 1000 then proceeds from 1030 to 1040.

[0091] At 1040, the climate controller determines whether the sealed electrical feedthrough is in a melted condition based on the one or more detected operating conditions of the sealed electrical feedthrough. For example, at 1040, the climate controller may determine whether the sealed electrical feedthrough is in a melted condition by comparing each of the detected operating condition(s) of the sealed electrical feedthrough to a corresponding predetermined threshold / limit.

[0092] In some embodiments, determining whether the sealed electrical feedthrough is in a melted condition at 1040 may include comparing the detected suction pressure to a predetermined suction pressure threshold at 1042 and / or comparing the detected amperage to a predetermined amperage draw limit at 1044. At 1042, the climate controller compares the detected suction pressure of the compressor (e.g., the suction pressure detected at 1032) to the predetermined suction pressure threshold. The climate controller may be configured to determine, at 1042, that the sealed electrical feedthrough is in a melted condition when the detected suction pressure is less than the predetermined suction pressure threshold.

[0093] At 1044, the climate controller compares the detected amperage of the power supplied to the sealed electrical feedthrough (e.g., the amperage detected at 1034, etc.) to a predetermined amperage draw limit. The climate controller can be configured to determine that the sealed electrical feedthrough is in a melting condition when the detected amperage exceeds the predetermined amperage draw limit. In one embodiment, the predetermined amperage draw limit can be based on an amperage that would cause the potting of the sealed electrical feedthrough to reach a potting melting point (e.g., an amperage that would heat the electrical pin(s) to the potting melting point). For example, the predetermined amperage draw can be higher than the normal maximum operating current of the compressor motor (e.g., higher than an expected inrush current, etc.) and lower than an amperage that would cause the potting to heat to the potting melting point. For example, a detected amperage exceeding the predetermined amperage draw limit indicates an increase in current consumed by the motor, which could ultimately cause the current consumed by the motor to reach an amperage that would cause the potting to heat to the potting melting point. Method 1000 then proceeds from 1040 to 1050.

[0094] At 1050, when it is determined that the sealed electrical feedthrough is in a melted condition, method 1000 proceeds to 1060. When it is determined that the sealed electrical feedthrough is not operating in a melted condition, the method returns to 1010. For example, the climate controller returns to 1010 and continues regulating the climate-controlled space by the climate control loop when it is determined that the sealed electrical feedthrough is not operating in a melted condition.

[0095] At 1060, the operation of the climate control loop is adjusted so that the sealed electrical feedthrough is no longer in a melted condition. For example, the climate controller controls the climate control loop so that the sealed electrical feedthrough is no longer operating in a melted condition. In some embodiments, at 1060, the adjustment of the climate control loop may include: at 1062, further opening an EEV (e.g., EEV 140) of the climate control loop and / or at 1064, disconnecting an electrical circuit breaker (e.g., electrical circuit breaker 172) that conducts power to the compressor. In one embodiment, at 1060, the adjustment of the climate control loop may include adjusting the operation of the compressor (e.g., adjusting the current provided by the power system 160, etc.).

[0096] At 1062, the climate controller further opens the EEV (e.g., at 1016, further opens the EEV from its valve position, etc.) such that the sealed electrical feedthrough is no longer in a melted condition. The opening of the EEV increases the flow rate of the working fluid through the EEV. The increase in the flow rate of the working fluid causes an increase in the suction pressure of the compressor. In one embodiment, the climate controller can be configured to further open the EEV at 1062 in response to the sealed electrical feedthrough being in a melted condition (as determined at 1042 based on the suction pressure). At 1062, the EEV is further opened by at least an amount such that the sealed electrical feedthrough is no longer in a melted condition. For example, the climate controller can be configured to further open the EEV at 1062 such that the suction pressure of the compressor is at or above a predetermined suction pressure threshold.

[0097] In one embodiment, at 1062, the climate control device may adjust the EEV from its first valve position (e.g., a first valve position based on controlling the superheat of the heated working fluid based on the temperature T1 of the heated working fluid, etc.) to a second valve position. In one embodiment, at 1062, opening the EEV reduces the conditioning provided to the climate-controlled space. For example, opening the EEV may cause the evaporator to provide less air cooling, causing the climate control loop to provide less cooling to the climate-controlled space. This conditioning may result in the climate control loop being unable to provide adequate conditioning, and the climate-controlled space being conditioned to a temperature above the temperature set point of the climate-controlled space.

[0098] In one embodiment, at 1062, in addition to maintaining the EEV further open (e.g., operating so that a modification similar to the adjustment from the first valve step to the second valve step is made based on each valve position of the EEV providing climate conditioning, etc.), method 1000 may also include continuing to operate the climate control loop as described for 1010 to provide conditioning to the climate-controlled space. For example, the climate controller may be configured to maintain the EEV further open until an indication is given that the suction pressure problem has been resolved. The operator and / or technician may indicate that the climate controller leak has been repaired, for example, via an HMI (e.g., HMI 190) and / or a telematics unit (e.g., telematics unit 192) connected to the TCCS. In such an embodiment, method 1000 will remain at 1062 or a subsequent step of 1060 (e.g., 1070) until such indication is received. Upon receiving an indication that the current intensity problem has been repaired, method 1000 may return to 1010. For example, the climate controller may be configured to close the electrical circuit breaker upon receiving an indication that the current intensity problem has been repaired.

[0099] At 1064, the climate controller disconnects an electrical circuit breaker of the power system (e.g., electrical circuit breaker 172) to interrupt the flow of power to the compressor's motor. When the electrical circuit breaker is disconnected, no power flows through the sealed electrical feedthrough, and the sealed electrical feedthrough is no longer in a melted condition (e.g., the current intensity through the sealed electrical feedthrough is zero, which is less than a predetermined current consumption limit, etc.). When no power is provided to the compressor's motor, the compressor shuts down. In one embodiment, at 1064, the climate controller can be configured to disconnect the electrical circuit breaker in response to the sealed electrical feedthrough being in a melted condition (as determined at 1042 based on the suction pressure, and / or determined at 1044 based on the current intensity of the mechanical power). The disconnected circuit also prevents the motor / compressor from starting.

[0100] In some embodiments, method 1000 may include maintaining an open circuit breaker until the climate controller receives an indication that a melt condition (e.g., a problem causing low suction pressure, a problem causing high amperage, etc.) has been corrected. For example, the climate controller may be configured to maintain an open circuit breaker (e.g., not close an open circuit breaker, etc.) until an indication is received that the amperage problem and / or suction pressure has been corrected. An operator and / or technician may indicate, for example, via an HMI (e.g., HMI 190) and / or a telematics unit (e.g., telematics unit 192) connected to the TCCS that the melt condition has been corrected. In such an embodiment, method 1000 will remain at 1062 or a subsequent step of 1060 (e.g., 1070) until such indication is received. Upon receiving an indication that the amperage problem has been corrected, method 1000 may return to 1010. For example, the climate controller may be configured to close the circuit breaker upon receiving an indication that the amperage problem has been corrected (e.g., a technician has replaced the compressor, etc.). Method 1000 may then proceed to optional 1070, or method 1000 may end.

[0101] At optional 1070, the climate controller issues a warning that a melt condition of the sealed electrical feedthrough has occurred. The warning may include how to resolve the melt condition. For example, the warning may include that the compressor has been shut down by opening an electrical circuit breaker at 1064 or increasing the opening of the EEV at 1064. In one embodiment, issuing the warning 1060 may include an HMI connected to the climate controller displaying a warning to warn an operator of the climate controlled transport unit (e.g., climate controlled transport unit 1). In one embodiment, issuing the warning 1060 may include an onboard information service unit (e.g., onboard information service unit 192) connected to the climate controller wirelessly sending the warning to a remote device (e.g., a computer, a server, a server network, etc.).

[0102] aspect:

[0103] Any of aspects 1 to 13 may be combined with any of aspects 14 to 20.

[0104] Aspect 1. A method for feedthrough protection and overcurrent protection of a hermetic compressor, wherein the hermetic compressor is used in a transport climate control system (TCCS) that provides climate control within a climate-controlled space of a transport unit, the TCCS including a climate control circuit having a hermetic compressor, the hermetic compressor including a housing and a motor located within the housing, the method comprising:

[0105] operating the hermetic compressor to compress a working fluid by providing electrical power to the electric motor of the hermetic compressor via a hermetic electrical feedthrough within the housing of the hermetic compressor;

[0106] detecting an operating parameter of the sealed electrical feedthrough;

[0107] determining whether the sealed electrical feedthrough is in a melted condition based on the detected operating parameter; and

[0108] Upon determining that the sealed electrical feedthrough is in the melted condition, operation of the climate control loop is adjusted until the sealed electrical feedthrough is no longer in the melted condition.

[0109] Aspect 2. The method according to aspect 1,

[0110] detecting the operating parameter includes detecting a current intensity of power provided to the sealed electrical feedthrough, and

[0111] Determining whether the sealed electrical feedthrough is in a melted condition includes comparing the amperage of the detected electrical power to a predetermined amperage draw limit.

[0112] Aspect 3. The method according to any one of aspects 1 and 2,

[0113] supplying power to the electric motor includes supplying power from a power source of the TCCS to the sealed electrical feedthrough via an electrical circuit breaker, and

[0114] Adjusting operation of the climate control loop includes opening the electrical circuit breaker to interrupt power from the power source to the sealed electrical feedthrough.

[0115] Aspect 4. The method of aspect 3, wherein providing power from the power source to the sealed electrical feedthrough via the electrical circuit breaker comprises converting the power provided from the power source from direct current to alternating current via an inverter.

[0116] Aspect 5. The method of any one of aspects 1 to 4, wherein providing power to the electric motor via the sealed electrical feedthrough comprises providing power from a power source of the TCCS to the sealed electrical feedthrough via a contactor, and

[0117] Detecting the operating parameter of the sealed electrical feedthrough includes detecting a positional state of the contactor, the positional state of the contactor corresponding to a current intensity of electrical power provided through the sealed electrical feedthrough.

[0118] Aspect 6. According to the method of any one of aspects 1 to 5, detecting the operating parameter comprises detecting the suction pressure of the hermetic compressor, and

[0119] Determining whether the sealed electrical feedthrough is in the melted condition includes comparing the detected suction pressure to a predetermined suction pressure threshold.

[0120] Aspect 7. The method according to aspect 6, wherein when the suction pressure of the sealed compressor is lower than the predetermined suction pressure threshold, the internal space of the housing along the sealed electrical feedthrough is lower than atmospheric pressure.

[0121] Aspect 8. The method according to any one of aspects 1 to 7, wherein adjusting the operation of the climate control loop comprises further opening an electronic expansion valve (EEV) of the climate control loop.

[0122] Aspect 9. The method of aspect 7, wherein further opening of the EEV reduces conditioning provided by the climate control loop to the climate-controlled space of the transport unit.

[0123] Aspect 10. The method according to any one of aspects 1 to 9, further comprising:

[0124] operating the climate control loop to provide conditioning for the climate-controlled space of the transport unit based on a temperature set point for the climate-controlled space, wherein operating the climate control loop to provide the conditioning comprises:

[0125] operating the hermetic compressor to compress the working fluid, and

[0126] adjusting an electronic expansion valve (EEV) of the climate control circuit to a first valve position based on the temperature of the working fluid,

[0127] Wherein adjusting the operation of the climate control loop includes further opening the EEV to a second valve position different from the first valve position.

[0128] Aspect 11. The method of any one of aspects 1 to 10, wherein the operating parameters of the electrical feedthrough are not used in a startup sequence of the hermetic compressor.

[0129] Aspect 12. The method according to any one of aspects 1 to 11, wherein the working fluid comprises a flammable refrigerant.

[0130] Aspect 13. The method according to any one of aspects 1 to 12, wherein the hermetic compressor is at least one of a hermetic compressor and a semi-hermetic compressor.

[0131] Aspect 14. A transport climate control system (TCCS) for providing climate control within a climate-controlled space of a transport unit, the TCCS comprising:

[0132] A climate control circuit comprising:

[0133] A hermetic compressor for compressing a working fluid, the hermetic compressor comprising a housing, an electric motor within the housing, and a hermetic electrical feedthrough within the housing,

[0134] a condenser for cooling the working fluid,

[0135] an expansion valve for expanding the working fluid, and

[0136] an evaporator for heating the working fluid;

[0137] power supply;

[0138] A climate controller configured as follows:

[0139] operating the climate control circuit to provide conditioning to the climate-controlled space of the transport unit, the conditioning comprising providing power from the power source to the electric motor via the sealed electrical feedthrough,

[0140] detecting an operating parameter of the sealed electrical feedthrough;

[0141] determining whether the sealed electrical feedthrough is in a melted condition based on the detected operating parameter;

[0142] When the sealed electrical feedthrough is in the melted condition, operation of the climate control loop is adjusted until the sealed electrical feedthrough is no longer in the melted condition.

[0143] Aspect 15. The TCCS according to Aspect 14, wherein the climate controller is configured to:

[0144] detecting the current intensity of the electrical power passing through the sealed electrical feedthrough to detect the operating parameter of the sealed electrical feedthrough, and

[0145] The sealed electrical feedthrough is determined to be in a melted condition based on comparing the detected amperage of the electrical power to a predetermined amperage draw limit.

[0146] Aspect 16. The TCCS according to any one of aspects 14 and 15, further comprising:

[0147] an electrical circuit breaker electrically connecting the power source to the sealed electrical feedthrough, wherein

[0148] The climate controller is configured to open the electrical circuit breaker to interrupt power provided to the electric motor via the sealed electrical feedthrough in order to adjust operation of the climate control circuit such that the sealed electrical feedthrough is no longer in a melted condition.

[0149] Aspect 17. The TCCS according to any one of aspects 14 to 16, further comprising:

[0150] a contactor electrically connecting the power source to the sealed electrical feedthrough, wherein

[0151] The climate controller is configured to detect a position state of the contactor to detect one or more operating parameters of the sealed electrical feedthrough, the position state of the contactor corresponding to a amperage of electrical power provided through the sealed electrical feedthrough.

[0152] Aspect 18. The TCCS according to any one of aspects 14 to 17, wherein the climate controller is configured to:

[0153] detecting the suction pressure of the hermetic compressor in order to detect the operating parameter, and

[0154] The sealed electrical feedthrough is determined to be in a melted condition based on comparing the detected suction pressure to a predetermined suction pressure threshold.

[0155] Aspect 19. The TCCS according to any one of aspects 14 to 18,

[0156] The expansion valve is an electronic expansion valve (EEV), and

[0157] The climate controller is configured to further open the electronic expansion valve to adjust operation of the climate control circuit such that the sealed electrical feedthrough is no longer in a melted condition.

[0158] Aspect 20. The TCCS according to any one of aspects 14 to 19, wherein the hermetic compressor is a hermetic compressor or a semi-hermetic compressor.

[0159] The examples disclosed in this application are to be considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes that fall within the meaning and range of equivalents of the claims are encompassed.

Claims

1. A method for feedthrough protection and overcurrent protection of a hermetic compressor, the hermetic compressor being used in a transport climate control system that provides climate control within a climate-controlled space of a transport unit, the transport climate control system including a climate control circuit having a hermetic compressor, the hermetic compressor including a housing and a motor located within the housing, the method comprising: operating the hermetic compressor to compress a working fluid by providing electrical power to the electric motor of the hermetic compressor via a hermetic electrical feedthrough within the housing of the hermetic compressor; detecting one or more operating parameters of the sealed electrical feedthrough, the detecting one or more operating parameters comprising detecting one or more of a amperage of power provided to the sealed electrical feedthrough and a suction pressure of the sealed compressor; Determining whether the sealed electrical feedthrough is in a melted condition based on the detected one or more operating parameters includes one or more of: comparing the detected amperage of the electrical power to a predetermined amperage consumption limit based on a minimum amperage that causes melting of a potting body of the sealed electrical feedthrough; and comparing the detected inhalation pressure with a predetermined inhalation pressure threshold; as well as Upon determining that the sealed electrical feedthrough is in the melted condition, operation of the climate control loop is adjusted until the sealed electrical feedthrough is no longer in the melted condition.

2. The method according to claim 1, characterized in that said detecting said one or more operating parameters comprises said detecting said amperage of power supplied to said sealed electrical feedthrough, and Determining whether the sealed electrical feedthrough is in a melted condition includes comparing the amperage of the detected electrical power to the predetermined amperage draw limit.

3. The method according to claim 1, characterized in that Providing power to the electric motor includes providing power from a power source of the transportation climate control system to the sealed electrical feedthrough via an electrical circuit breaker, and Adjusting operation of the climate control loop includes opening the electrical circuit breaker to interrupt power from the power source to the sealed electrical feedthrough.

4. The method according to claim 3, characterized in that Providing electrical power from the power source to the sealed electrical feedthrough via the electrical circuit breaker includes converting the power provided from the power source from direct current to alternating current via an inverter.

5. The method according to claim 1, wherein Providing power to the electric motor via the sealed electrical feedthrough includes providing power from a power source of the transportation climate control system to the sealed electrical feedthrough via a contactor, and Detecting the operating parameter of the sealed electrical feedthrough includes detecting a positional state of the contactor, the positional state of the contactor corresponding to a current intensity of electrical power provided through the sealed electrical feedthrough.

6. The method according to claim 1, characterized in that The detecting of the one or more operating parameters comprises detecting the suction pressure of the hermetic compressor, and Determining whether the sealed electrical feedthrough is in the melted condition includes comparing the detected suction pressure to the predetermined suction pressure threshold.

7. The method according to claim 6, characterized in that When the suction pressure of the hermetic compressor is lower than the predetermined suction pressure threshold, the pressure of the interior space of the housing along the hermetic electrical feedthrough is lower than atmospheric pressure.

8. The method according to claim 1, characterized in that Adjusting operation of the climate control loop includes further opening an electronic expansion device of the climate control loop.

9. The method according to claim 8, characterized in that Further opening of the electronic expansion device reduces the conditioning provided by the climate control circuit to the climate-controlled space of the transport unit.

10. The method according to any one of claims 1 to 9, characterized in that Also includes: operating the climate control loop to provide conditioning for the climate-controlled space of the transport unit based on a temperature set point for the climate-controlled space, wherein operating the climate control loop to provide the conditioning comprises: operating the hermetic compressor to compress the working fluid, and adjusting an electronic expansion valve of the climate control circuit to a first valve position based on the temperature of the working fluid, Wherein, adjusting the operation of the climate control circuit includes further opening the electronic expansion valve to a second valve position different from the first valve position.

11. The method according to claim 1, wherein The detecting of the one or more operating parameters of the hermetic electrical feedthrough is not in response to a start-up sequence of the hermetic compressor; and / or The working fluid comprises a flammable refrigerant; and / or The sealed compressor is a hermetic compressor or a semi-hermetic compressor.

12. A transport climate control system for providing climate control within a climate-controlled space of a transport unit, the transport climate control system comprising: A climate control circuit comprising: A hermetic compressor for compressing a working fluid, the hermetic compressor comprising a housing, an electric motor within the housing, and a hermetic electrical feedthrough within the housing, a condenser for cooling the working fluid, an expansion valve for expanding the working fluid, and an evaporator for heating the working fluid; power supply; A climate controller configured as follows: operating the climate control circuit to provide conditioning to the climate-controlled space of the transport unit, the conditioning comprising providing power from the power source to the electric motor via the sealed electrical feedthrough, detecting one or more operating parameters of the sealed electrical feedthrough, the detecting one or more operating parameters comprising detecting one or more of a amperage of power provided to the sealed electrical feedthrough and a suction pressure of the sealed compressor; Determining whether the sealed electrical feedthrough is in a melted condition based on the detected one or more operating parameters includes one or more of: comparing the detected amperage of the electrical power to a predetermined amperage consumption limit based on a minimum amperage that causes melting of a potting body of the sealed electrical feedthrough; and comparing the detected inhalation pressure with a predetermined inhalation pressure threshold; When the sealed electrical feedthrough is in the melted condition, operation of the climate control loop is adjusted until the sealed electrical feedthrough is no longer in the melted condition.

13. The transportation climate control system of claim 12, wherein: The climate controller is configured as follows: detecting the current intensity of the electrical power passing through the sealed electrical feedthrough to detect the operating parameter of the sealed electrical feedthrough, and determining that the sealed electrical feedthrough is in a melted condition based on comparing the detected amperage of the electrical power to the predetermined amperage draw limit; and / or The transportation climate control system further comprises: an electrical circuit breaker electrically connecting the power source to the sealed electrical feedthrough, wherein the climate controller being configured to open the electrical circuit breaker to interrupt power provided to the electric motor via the sealed electrical feedthrough so as to adjust operation of the climate control circuit such that the sealed electrical feedthrough is no longer in a melted condition; and / or The transportation climate control system further comprises: a contactor electrically connecting the power source to the sealed electrical feedthrough, wherein the climate controller being configured to detect a position state of the contactor to detect one or more operating parameters of the sealed electrical feedthrough, the position state of the contactor corresponding to a amperage of electrical power provided through the sealed electrical feedthrough; and / or The climate controller is configured as follows: detecting the suction pressure of the hermetic compressor in order to detect the operating parameter, and The sealed electrical feedthrough is determined to be in a melted condition based on comparing the detected suction pressure to the predetermined suction pressure threshold.

14. The transportation climate control system of claim 12, wherein: The expansion valve is an electronic expansion valve, and The climate controller is configured to further open the electronic expansion valve to adjust operation of the climate control circuit such that the sealed electrical feedthrough is no longer in a melted condition.

15. The transportation climate control system of claim 12, wherein: The sealed compressor is a hermetic compressor or a semi-hermetic compressor.

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