System and method for adjusting position of compressor

Abstract

The present disclosure relates to a method for heating, ventilation, air conditioning and refrigeration (HVACamp; a system (10) for operating a compressor (20, R) includes a compressor (32) having a housing (100), a shaft (102) disposed within and extending through the housing (100), and an impeller (104) coupled to the shaft (102), where the shaft (102) is configured to rotate relative to the housing (100) and about an axis (120) to rotate the impeller (104). The HVACamp; the R system (10) also includes a controller (134) configured to receive data indicative of a distance from a shroud (204) of the impeller (104) to the housing (100) and adjust a position of the shaft (102) along the axis (120) based on a comparison of the distance from the shroud (204) of the impeller (104) to the housing (100) to a predetermined value.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Application Serial No. 63 / 342,410, filed on May 16, 2022, entitled “SYSTEM AND METHOD FOR ADJUSTING POSITION OF A COMPRESSOR,” and U.S. Provisional Application Serial No. 63 / 387,177, filed on December 13, 2022, entitled “SYSTEM AND METHOD FOR ADJUSTING POSITION OF A COMPRESSOR,” the entire contents of which are hereby incorporated by reference for all purposes. Background Art

[0003] This section is intended to introduce the reader to various aspects of the technology that may be related to various aspects of the present disclosure described below. It is believed that this discussion helps to provide the reader with background information to promote a better understanding of various aspects of the present disclosure. Therefore, it should be understood that these statements should be read in this light, rather than as an admission of the prior art.

[0004] A chiller system or vapor compression system utilizes a working fluid (e.g., a refrigerant) that changes phase between vapor, liquid, and combinations thereof in response to exposure to different temperatures and pressures within the chiller system components. A chiller system may allow a working fluid to be in heat exchange relation with a cooling fluid (e.g., water), and may deliver the cooling fluid to a conditioning device and / or a regulated environment served by the chiller system. In such applications, the cooling fluid may be directed through downstream equipment such as an air handler to regulate other fluids, such as the air in a building. The chiller system may include a compressor configured to pressurize the working fluid and circulate the working fluid through a working fluid circuit. Unfortunately, the compressor may be susceptible to inefficient or undesirable operation. Summary of the invention

[0005] The following describes a summary of certain embodiments disclosed herein. It should be understood that these aspects presented are only intended to provide the reader with a brief summary of certain embodiments, and these aspects are not intended to limit the scope of the present disclosure. In fact, the present disclosure may encompass various aspects that may not be described below.

[0006] In one embodiment, a heating, ventilation, air conditioning and refrigeration (HVAC&R) system includes a compressor having a housing, a shaft disposed within and extending through the housing, and an impeller coupled to the shaft, wherein the shaft is configured to rotate relative to the housing and about an axis to rotate the impeller. The HVAC&R system also includes a controller configured to receive data indicating a distance from a shroud of the impeller to the housing, and adjust a position of the shaft along the axis based on a comparison of the distance from the shroud of the impeller to the housing with a predetermined value.

[0007] In another embodiment, a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system includes a controller configured to receive data indicating a distance from a shroud of an impeller to a casing of the compressor from a sensor disposed within a compressor, compare the distance to a predetermined value, and adjust a position of a shaft coupled to the impeller along a rotational axis of the shaft based on the comparison of the distance from the impeller to the casing to the predetermined value to adjust a position of the impeller relative to the casing.

[0008] In a further embodiment, a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system includes a compressor having a housing, a shaft disposed within and extending through the housing, a thrust bearing disposed within the housing and coupled to the shaft, and an impeller disposed within the housing and coupled to the shaft, wherein the impeller includes a plurality of blades and a shroud secured to the plurality of blades. The HVAC&R system also includes a controller configured to control operation of the thrust bearing based on data indicating a detected distance from the housing to the shroud of the impeller. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various aspects of the present disclosure may be better understood after reading the following detailed description and referring to the drawings, in which:

[0010] Figure 1 is a perspective view of a building in which an embodiment of a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system may be utilized in a commercial environment according to an aspect of the present disclosure;

[0011] Figure 2 is a perspective view of an embodiment of a vapor compression system according to an aspect of the present disclosure;

[0012] Figure 3 According to one aspect of the present disclosure Figure 2 A schematic diagram of an embodiment of a vapor compression system;

[0013] Figure 4 According to one aspect of the present disclosure Figure 2 A schematic diagram of an embodiment of a vapor compression system;

[0014] Figure 5is a cross-sectional side view of an embodiment of a compressor of an HVAC&R system according to an aspect of the present disclosure;

[0015] Figure 6 is a cross-sectional side view of an embodiment of a portion of a compressor of an HVAC&R system according to an aspect of the present disclosure;

[0016] Figure 7 is a cross-sectional side view of an embodiment of a portion of a compressor of an HVAC&R system according to an aspect of the present disclosure;

[0017] Figure 8 is a cross-sectional side view of an embodiment of a portion of a compressor of an HVAC&R system according to an aspect of the present disclosure; and

[0018] Fig. 9 is a flow chart of an embodiment of a method for operating a compressor of an HVAC&R system according to an aspect of the present disclosure. DETAILED DESCRIPTION

[0019] One or more specific embodiments will be described below. In order to provide a concise description of these embodiments, not all features of the actual implementation scheme are described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, a large number of implementation-specific decisions must be made to achieve the developer's specific goals, such as complying with system-related and business-related constraints, which may vary from implementation to implementation. In addition, it should be understood that such development work may be complex and time-consuming, but is no more than a routine task of design, manufacturing, and production for ordinary technicians who benefit from this disclosure.

[0020] When introducing elements of various embodiments of the present disclosure, the articles "a," "an," and "the" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements in addition to the listed elements. Additionally, it should be understood that references to "one embodiment" or "an embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that are further incorporated into the recited features.

[0021] As used herein, the terms "approximately," "substantially," and "substantially," etc., are intended to convey that the value of the property being described may be within a relatively small range of the value of the property, as understood by a person skilled in the art. For example, when a property value is described as being "approximately" equal to (or, for example, "substantially similar to") a given value, this is intended to convey that the property value may be within + / -5%, within + / -4%, within + / -3%, within + / -2%, within + / -1%, or even closer to the given value. Similarly, when a given feature is described as being "substantially parallel" to another feature, "substantially perpendicular" to another feature, etc., this is intended to mean that the given feature has the described property within + / -5%, within + / -4%, within + / -3%, within + / -2%, within + / -1%, or even closer, such as being parallel to another feature, perpendicular to another feature, etc. Additionally, it should be understood that mathematical terms such as "planar," "inclined," "perpendicular," "parallel," etc., are intended to encompass features of surfaces or elements as understood by one of ordinary skill in the relevant art, and should not be interpreted as strictly as would be understood in the mathematical arts. For example, a "planar" surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within relevant tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface with a "slope" is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., inclined) relative to a reference point using techniques and tools available to one of ordinary skill in the art.

[0022] Embodiments of the present disclosure relate to a heating, ventilation, air conditioning and / or refrigeration (HVAC&R) system including a vapor compression system (e.g., a vapor compression loop) having a compressor. In operation, the compressor can pressurize a working fluid within the vapor compression system and direct the working fluid to a condenser, which can cool and condense the working fluid. The condensed working fluid can be directed to an expansion device, which can reduce the pressure of the working fluid, thereby further cooling the working fluid. The cooled working fluid can be directed from the expansion device to an evaporator, in which the working fluid can be placed in a heat exchange relationship with a conditioning fluid to cool the conditioning fluid.

[0023] In some embodiments, the compressor may include an impeller configured to rotate to pressurize the working fluid and guide the working fluid to the diffuser channel of the compressor. For example, the impeller may be coupled to a shaft, and the shaft may be configured to rotate relative to the housing of the compressor to drive the impeller to rotate relative to the housing. However, during the operation of the compressor, the geometry and / or position of the impeller (e.g., relative to the housing and / or diffuser channel) may change and affect the performance of the compressor. As an example, the position of the impeller may be moved so that the outlet or discharge port of the impeller may be offset (e.g., misaligned) relative to the opening of the diffuser channel. The offset between the discharge port of the impeller and the opening of the diffuser channel may reduce the efficiency of the compressor. For example, the misalignment between the discharge port of the impeller and the opening of the diffuser channel may interrupt, disturb or interfere with the working fluid flow through the compressor (e.g., from the impeller to the diffuser channel). The disturbance of the working fluid flow through the compressor may cause a pressure loss or a head loss, thereby reducing the efficiency of the working fluid flow through the compressor. In additional or alternative embodiments, the position of the impeller may be offset toward the housing and may increase the likelihood of contact between the impeller (e.g., a shroud of the impeller, the tips of the blades of the impeller) and the housing. Such contact may affect the structural integrity of the impeller and / or the housing and / or may interrupt or disrupt the operation of the compressor.

[0024] Therefore, it is now recognized that maintaining a desired position of an impeller during operation (e.g., within a housing of a compressor) can improve performance, reduce wear, and / or increase the useful life of the compressor. Therefore, the present disclosure relates to a system and method for monitoring the position of an impeller and adjusting the position of the impeller (e.g., relative to the housing) based on the monitored position. For example, an operating parameter value indicating the position of the impeller may be received, such as from a sensor of the compressor. In some embodiments, the operating parameter may include a distance between a surface of the impeller and the housing of the compressor. As an example, the surface of the impeller may be a surface of a shroud of the impeller. As another example, the surface of the impeller may be the tip of a blade of the impeller. In response to a determination that the distance between the surface of the impeller and the housing of the compressor is different from a predetermined distance value and / or outside a range of distance values ​​(e.g., a target range, a threshold range), the position of the shaft to which the impeller is attached may be adjusted to move the impeller relative to the housing. For example, the shaft may translate (e.g., by control of a thrust bearing coupled to the shaft) to move the impeller relative to the housing, thereby adjusting the distance between the surface of the impeller and the housing to within the range of distance values.

[0025] In some cases, the predetermined distance value and / or the range of distance values ​​can be associated with the desired alignment between the discharge port of the impeller and the opening of the diffuser passage and / or the desired clearance between the impeller and the housing. Therefore, adjusting the position of the shaft and the impeller to approximately equal the predetermined distance value and / or within the range of distance values ​​can achieve the desired alignment between the discharge port of the impeller and the opening of the diffuser passage, and / or provide the desired clearance between the impeller and the housing. For example, maintaining the position of the shaft and the impeller within the range of distance values ​​can improve the efficient operation of the compressor. In fact, the disclosed technology can achieve the position adjustment of the impeller in the housing of the compressor (e.g., the discharge port of the impeller is aligned with the opening of the diffuser passage) during the operation of the compressor, such as in response to the variable operating conditions of the compressor. In this way, the operation of the compressor can be improved across the variable operating conditions of the compressor (e.g., more efficiently).

[0026] Turning now to the accompanying drawings, Figure 1 1 is a perspective view of an embodiment of an environment for a heating, ventilation, air conditioning, and refrigeration (HVAC&R) system 10 in a building 12 for a typical commercial environment. The HVAC&R system 10 may include a vapor compression system 14 (e.g., a chiller) that supplies a cooling liquid that can be used to cool the building 12. The HVAC&R system 10 may also include a boiler 16 for supplying warm liquid to heat the building 12 and an air distribution system that circulates air through the building 12. The air distribution system may also include air return ducts 18, air supply ducts 20, and / or air handlers 22. In some embodiments, the air handler 22 may include a heat exchanger that is connected to the boiler 16 and the vapor compression system 14 via ducts 24. Depending on the operating mode of the HVAC&R system 10, the heat exchanger in the air handler 22 may receive heated liquid from the boiler 16 or cooled liquid from the vapor compression system 14. The HVAC&R system 10 is shown with separate air handlers on each floor of the building 12, but in other embodiments, the HVAC&R system 10 may include air handlers 22 and / or other components that may be shared between floors.

[0027] Figure 2 and Figure 3 is an embodiment of a vapor compression system 14 that may be used in the HVAC&R system 10. The vapor compression system 14 may circulate a refrigerant through a circuit beginning with a compressor 32. The circuit may also include a condenser 34, an expansion valve or device 36, and a liquid cooler or evaporator 38. The vapor compression system 14 may further include a control panel 40 having an analog-to-digital (A / D) converter 42, a microprocessor 44, a non-volatile memory 46, and / or an interface board 48.

[0028] Some examples of fluids that can be used as refrigerants in the vapor compression system 14 are hydrofluorocarbon (HFC) based refrigerants, such as R-410A, R-407, R-134a, R-1233zd, R-1234ze, hydrofluoroolefins (HFO), "natural" refrigerants such as ammonia (NH3), R-717, carbon dioxide (CO2), R-744 or hydrocarbon-based refrigerants, water vapor, or any other suitable refrigerant. In some embodiments, the vapor compression system 14 can be configured to efficiently utilize a refrigerant having a standard boiling point of about 19 degrees Celsius (66 degrees Fahrenheit) at one atmosphere of pressure, which is also referred to as a low-pressure refrigerant relative to a medium-pressure refrigerant such as R-134a. As used herein, "standard boiling point" can refer to a boiling point temperature measured at one atmosphere of pressure.

[0029] In some embodiments, the vapor compression system 14 may use one or more of a variable speed drive (VSD) 52, a motor 50, a compressor 32, a condenser 34, an expansion valve or device 36, and / or an evaporator 38. The motor 50 may drive the compressor 32 and may be powered by the variable speed drive (VSD) 52. The VSD 52 receives AC power having a specific fixed line voltage and a fixed line frequency from an alternating current (AC) power source and provides power having a variable voltage and frequency to the motor 50. In other embodiments, the motor 50 may be powered directly by an AC or direct current (DC) power source. The motor 50 may include any type of motor that may be powered by a VSD or directly by an AC or DC power source, such as a switched reluctance motor, an induction motor, an electronically commutated permanent magnet motor, or another suitable motor.

[0030] The compressor 32 compresses the refrigerant vapor and delivers the vapor to the condenser 34 through a discharge passage. In some embodiments, the compressor 32 may be a centrifugal compressor. The refrigerant vapor delivered to the condenser 34 by the compressor 32 may transfer heat to a cooling fluid (e.g., water or air) in the condenser 34. As a result of the heat transfer with the cooling fluid, the refrigerant vapor may condense into a refrigerant liquid in the condenser 34. The liquid refrigerant from the condenser 34 may flow to the evaporator 38 through the expansion device 36. Figure 3 In the illustrated embodiment, the condenser 34 is water cooled and includes a tube bundle 54 connected to a cooling tower 56 that supplies cooling fluid to the condenser 34 .

[0031] The liquid refrigerant delivered to the evaporator 38 may absorb heat from another cooling fluid, which may or may not be the same cooling fluid used in the condenser 34. The liquid refrigerant in the evaporator 38 may undergo a phase change from liquid refrigerant to refrigerant vapor. Figure 3As shown in the illustrated embodiment of FIG. 5 , the evaporator 38 may include a tube bundle 58 having a supply line 60S and a return line 60R connected to a cooling load 62. The cooling fluid of the evaporator 38 (e.g., water, ethylene glycol, calcium chloride brine, sodium chloride brine, or any other suitable fluid) enters the evaporator 38 through the return line 60R and leaves the evaporator 38 through the supply line 60S. The evaporator 38 may reduce the temperature of the cooling fluid in the tube bundle 58 by heat transfer with the refrigerant. The tube bundle 58 in the evaporator 38 may include multiple tubes and / or multiple tube bundles. In any case, the vapor refrigerant leaves the evaporator 38 and returns to the compressor 32 through the suction line to complete the cycle.

[0032] Figure 4 is a schematic diagram of vapor compression system 14 in which intermediate loop 64 is coupled between condenser 34 and expansion device 36. Intermediate loop 64 may have an inlet line 68 directly fluidly connected to condenser 34. In other embodiments, inlet line 68 may be indirectly fluidly coupled to condenser 34. Figure 4 In the illustrated embodiment, the inlet line 68 includes a first expansion device 66 positioned upstream of an intermediate vessel 70. In some embodiments, the intermediate vessel 70 may be a flash tank (e.g., a flash intercooler, an economizer, etc.). In other embodiments, the intermediate vessel 70 may be configured as a heat exchanger or a "surface economizer." Figure 4 In the illustrated embodiment of , the intermediate container 70 functions as a flash tank, and the first expansion device 66 is configured to reduce (e.g., expand) the pressure of the liquid refrigerant received from the condenser 34. During the expansion process, a portion of the liquid may evaporate, and thus the intermediate container 70 may be used to separate the vapor from the liquid received from the first expansion device 66.

[0033] Additionally, the intermediate container 70 can provide further expansion of the liquid refrigerant due to the pressure drop experienced by the liquid refrigerant when entering the intermediate container 70 (e.g., due to the rapid increase in volume experienced when entering the intermediate container 70). The vapor in the intermediate container 70 can be drawn by the compressor 32 through a suction line 74 (e.g., an interstage line) of the compressor 32. In other embodiments, the vapor in the intermediate container can be drawn to an intermediate stage (e.g., a non-suction stage) of the compressor 32. Due to expansion in the expansion device 66 and / or the intermediate container 70, the enthalpy of the liquid collected in the intermediate container 70 can be lower than the enthalpy of the liquid refrigerant leaving the condenser 34. The liquid from the intermediate container 70 can then flow through the second expansion device 36 in line 72 to the evaporator 38.

[0034] It should be understood that any of the features described herein can be combined with the vapor compression system 14 or any other suitable HVAC&R system. For example, the present technology can be combined with any HVAC&R system having an economizer (such as the intermediate container 70) and a compressor (such as the compressor 32). The following discussion describes the present technology in combination with an embodiment of the compressor 32 configured as a single-stage compressor. However, it should be noted that the systems and methods described herein can be combined with other embodiments of the compressor 32 and the HVAC&R system 10.

[0035] As described above, the present disclosure relates to a system and method for adjusting an impeller of a compressor to achieve and / or maintain a desired position of the impeller within the housing of the compressor. For example, the distance between the surface of the impeller and the housing of the compressor can be detected and / or monitored. Based on a determination that the distance is not equal to a predetermined distance value and / or is outside a range of distance values ​​associated with the desired position of the impeller, the position of the impeller can be adjusted. For example, the impeller can be coupled to a shaft, and the position of the shaft can be adjusted to adjust the distance between the surface of the impeller and the housing to within a range of distance values. In other words, the position of the shaft can be controlled to maintain the distance between the surface of the impeller and the housing within a range of distance values ​​and / or to be approximately equal to a predetermined distance value. In this way, the present technology can achieve adjustment of the position of the impeller, such as achieving alignment between the discharge port of the impeller and the inlet of the diffuser passage of the compressor, thereby enabling the compressor to operate more efficiently.

[0036] Considering the foregoing, Figure 5 is a cross-sectional side view of an embodiment of a compressor 32 of the HVAC&R system 10. The compressor 32 may include a housing 100 and a shaft 102 extending through the housing 100. The compressor 32 may also include an impeller 104 coupled to the shaft 102, such as via a fastener 106. During operation of the compressor 32, the shaft 102 may rotate (e.g., by operation of the motor 50) and cause the impeller 104 to rotate within the housing 100. The rotation of the impeller 104 may drive a working fluid (e.g., refrigerant) along a working fluid flow path 108 (e.g., from the evaporator 38, from the intermediate container 70) and draw the working fluid into the housing 100 and toward the impeller 104 via a suction port 110. The impeller 104 may impart mechanical energy to the working fluid and discharge the working fluid toward a diffuser passage 112 of the compressor 32 via an impeller outlet or discharge port 114 of the impeller 104. The working fluid may be directed from the diffuser passage 112 to a volute 116 of the compressor 32 , and from the volute 116 to another component of the HVAC&R system 10 (eg, the condenser 34 ) for heat exchange with a fluid, such as a cooling fluid.

[0037] In the illustrated embodiment, the compressor 32 includes a first bearing 118 (e.g., an axial bearing, a thrust bearing, a magnetic thrust bearing) configured to control and / or adjust the position (e.g., axial position) of the shaft 102 along an axis 120 (e.g., a longitudinal axis, an axis of rotation of the shaft 102) that extends along the length of the compressor 32. For example, the first bearing 118 can be configured to prevent or limit movement (e.g., translation) of the shaft 102 along and / or relative to the axis 120. The compressor 32 can also include a second bearing 122 (e.g., a first radial bearing) and a third bearing 124 (e.g., a second radial bearing). The second bearing 122 and the third bearing 124 can prevent movement (e.g., bending, radial movement, eccentric rotation) of the shaft 102 in a direction that intersects the axis 120.

[0038] In some embodiments, the first bearing 118 can be positioned at or coupled to a first end 126 (e.g., an axial end, a longitudinal end) of the shaft 102, and the impeller 104 can be positioned at or coupled to a second end 128 (e.g., an axial end, a longitudinal end) of the shaft 102 opposite the first end 126. Thus, the first bearing 118 and the impeller 104 can be positioned at opposite ends 126, 128 of the shaft 102. Additionally, in the illustrated embodiment, the second bearing 122 is positioned adjacent to the first bearing 118 at the first end 126 of the shaft 102, and the third bearing 124 is positioned adjacent to the impeller 104 at the second end 128 of the shaft 102. The positioning of the impeller 104 and the third bearing 124 at the second end 128 of the shaft 102 and the positioning of the first bearing 118 and the second bearing 122 at the first end 126 of the shaft 102 can enable the shaft 102 to perform desired rotation and / or other operations. For example, the arrangement of the impeller 104, the first bearing 118, the second bearing 122, and the third bearing 124 may enable stable (e.g., concentric) rotation of the shaft 102 and / or provide control over the respective positions of the impeller 104 and the shaft 102 (e.g., relative to the housing 100), such as relative to a system in which the first bearing 118 is positioned closer to the impeller 104 (e.g., at the second end 128). Further, the described arrangement of the illustrated embodiment may provide a more balanced weight and / or load distribution along the shaft 102, as well as improved stability during rotation of the shaft 102 and the impeller 104 during operation of the compressor 32.

[0039] As described above, during operation of the compressor 32, the impeller 104 may be susceptible to changes in geometry and / or position relative to the housing 100. As an example, rotation of the impeller 104 during operation of the compressor 32 may generate heat along the shaft 102, which may cause thermal growth and / or expansion of the shaft 102 (e.g., along the axis 120), which may drive the impeller 104 to move in a first direction 130 (e.g., a first axial direction) along the axis 120 relative to the housing 100. As another example, rotation of the impeller 104 may cause blades 131 of the impeller 104 to bend, deflect, or flex toward a portion of the housing 100. That is, during relatively large rotational speeds of the impeller 104 (e.g., an unshrouded or open impeller), the blades 131 may bend, pivot, rotate, or otherwise deflect outward (e.g., relative to, along the axis 120). In either example, one or more surfaces (eg, blade surfaces, shroud-facing surface, top surface) of the impeller 104 may be at least partially moved or offset relative to the housing 100 in the first direction 130 .

[0040] It can be appreciated that it may be desirable to limit, reduce, and / or adjust the movement of the impeller 104 along the axis 120, such as in response to movement or displacement of the impeller 104 within the housing 100 that may be caused during operation of the compressor 32. For example, movement of the impeller 104 along the axis 120 may cause the impeller outlet 114 and the diffuser passage 112 (e.g., relative to the flow direction of the working fluid therethrough) to be misaligned. Additionally, movement of the impeller 104 along the axis 120 may reduce a distance (e.g., a gap) between the impeller 104 and a portion of the housing 100. For example, movement of the impeller 104 along the first direction 130 may position the impeller 104 closer to a shroud housing portion 132 (e.g., a stationary portion, an impeller housing portion, a blade housing portion, a nozzle plate housing portion) of the housing 100. Such movement may adversely affect the performance and / or structural integrity of the compressor 32. For example, movement of the impeller 104 in the first direction 130 may cause contact between the impeller 104 (e.g., a shroud of the impeller 104, blades 131 of the impeller 104) and the shroud housing portion 132, which may cause wear or degradation of the impeller 104 and / or the casing 100. It may also be desirable to limit (e.g., reduce) the size of the distance (e.g., gap) between the impeller 104 and the shroud housing portion 132 of the casing 100 so as to enable improved (e.g., more efficient) operation of the compressor 32.

[0041] Thus, the HVAC&R system 10 may include a control system 134 (e.g., a controller, an automated controller, an electronic controller, a magnetic bearing controller) configured to operate the compressor 32 to mitigate and / or adjust the movement of the impeller 104 along the axis 120. For example, the control system 134 may be configured to monitor and / or adjust the position of the impeller 104 within the housing 100 to mitigate the misalignment of the impeller outlet 114 and the diffuser passage 112. The control system 134 may include a memory 136 and a processing circuit 138 (e.g., a microprocessor). The memory 136 may include a volatile memory, such as a random access memory (RAM), and / or a non-volatile memory, such as a read-only memory (ROM), an optical drive, a hard drive, a solid-state drive, or any other tangible, non-transitory computer-readable medium storing instructions that, when executed by the processing circuit 138, control the operation of the compressor 32. The processing circuit 138 may be configured to execute instructions stored on the memory 136. As examples, processing circuitry 138 may include one or more application specific integrated circuits (ASICs), one or more field programmable gate arrays (FPGAs), one or more general purpose processors, or any combination thereof. Processing circuitry 138 may include multiple microprocessors, one or more “general purpose” microprocessors, one or more special purpose microprocessors, and / or some combination thereof. For example, processing circuitry 138 may include one or more reduced instruction set computing (RISC) processors.

[0042] The control system 134 may be configured to adjust the position (e.g., axial position) of the impeller 104 along the axis 120 and / or relative to the housing 100. For example, the control system 134 may be configured to adjust the position of the shaft 102 along the axis 120 to drive the impeller 104 to move (e.g., adjust the position) along the axis 120. In some embodiments, the compressor 32 may include a collar 140 (e.g., a thrust collar) fixedly coupled to the shaft 102. Thus, movement of the collar 140 may cause corresponding movement of the shaft 102. The first bearing 118 may control movement of the collar 140 and, therefore, control movement (e.g., axial movement) of the shaft 102 and the impeller 104 along the axis 120. For example, the first bearing 118 may be a magnetic bearing assembly including a first magnetic bearing component or portion 142 (e.g., a first magnetic winding, a first electromagnet) and a second magnetic bearing component or portion 144 (e.g., a second magnetic winding, a second electromagnet). The collar 140 may be positioned between the magnetic bearing components 142, 144 (e.g., axially between them with respect to the axis 120), and each of the magnetic bearing components 142, 144 may apply a magnetic force to the collar 140 to adjust the position of the collar 140 along the axis 120. For example, the magnetic bearing components 142, 144 may have magnetic poles (e.g., a positive magnetic pole, a reverse magnetic pole) that apply a magnetic force to the collar 140.

[0043] In some cases, during operation of the compressor 32, the magnetic force applied by the magnetic bearing components 142, 144 can resist movement of the collar 140 along the axis 120. For example, the control system 134 can be configured to control the first bearing 118 to resist movement of the collar 140 along the axis 120 to maintain alignment of the impeller outlet 114 and the diffuser passage 112 (e.g., radial alignment relative to the axis 120). However, the collar 140 and, therefore, the shaft 102 can be freely rotated (e.g., by the motor 50) to drive rotation of the impeller 104. In some embodiments, the magnitude of the magnetic force (e.g., the total magnetic force) applied to the collar 140 by one or both of the magnetic bearing components 142, 144 can be adjustable. As an example, the magnetic force (e.g., the total magnetic force applied to the collar 140) can be increased to compensate for adjustment and / or movement of a portion of the shaft 102 (e.g., at the second end 128) that may otherwise occur due to thermal growth during operation of the compressor 32. In other words, thermal growth may cause the shaft 102 to undesirably move in a particular direction (e.g., in the first direction 130), and a magnetic force may be applied to the collar 140 via the magnetic bearing components 142, 144 to move the shaft 102 in a direction opposite to the particular direction (e.g., opposite to the first direction 130) to reduce or mitigate overall movement of the shaft 102, such as preventing movement of the shaft 102 toward the shield housing portion 132.

[0044] The control system 134 can be communicatively coupled to the first bearing 118 and can also be configured to control movement and / or position adjustment of the collar 140 and, therefore, the shaft 102 along the axis 120 via the magnetic bearing components 142, 144. For example, the control system 134 can be configured to adjust the current provided to the magnetic bearing components 142, 144 to adjust the magnetic force (e.g., total magnetic force, electromagnetic force, magnetic field) applied to the collar 140. The position (e.g., axial position) of the collar 140 between the magnetic bearing components 142, 144 can be adjusted by changing the magnetic force applied to the collar 140, such as by pushing and / or pulling the collar 140 along the axis 120 via the magnetic force.

[0045] In some embodiments, the compressor 32 may include one or more sensors that are communicatively coupled to the control system 134 and configured to detect one or more operating parameters of the compressor 32. The control system 134 may adjust the operation of the first bearing 118 based on feedback and / or data from the one or more sensors. For example, the compressor 32 may include a first sensor 146 (e.g., a proximity sensor, a position sensor, a capacitive sensor) that is configured to monitor an operating parameter indicative of an axial position of the impeller 104 (e.g., along the axis 120, relative to the housing 100). The first sensor 146 may transmit sensor data indicative of the operating parameter to the control system 134, and the control system 134 may control the first bearing 118 (e.g., magnetic bearing components 142, 144) to adjust the position of the collar 140 based on the sensor data received from the first sensor 146. As an example, the control system 134 may control the first bearing 118 to maintain a desired axial position of the collar 140, and thus maintain a desired axial position of the impeller 104 along the axis 120. In some embodiments, control system 134 may control first bearing 118 to maintain a desired axial position of collar 140 that correlates or corresponds to the alignment of impeller outlet 114 and diffuser passage 112 .

[0046] The compressor 32 may also include a second sensor 148 configured to monitor a position of the collar 140, such as relative to a position of the magnetic bearing components 142, 144 (e.g., along the axis 120). The second sensor 148 may transmit sensor data indicative of the position of the collar 140 to the control system 134, and the control system 134 may control the operation of the first bearing 118 to adjust the position of the collar 140 based on the sensor data received from the second sensor 148. For example, the control system 134 may control the first bearing 118 to maintain the position of the collar 140 within a predetermined range of positions of the collar 140. In some embodiments, the predetermined range of positions of the collar 140 may correspond to an alignment of the impeller outlet 114 with the diffuser passage 112. By controlling the magnetic bearing components 142, 144 to maintain the collar 140 within the predetermined range of collar positions, contact between the collar 140 and the magnetic bearing components 142, 144 may be avoided. As an example, the control system 134 may control the first bearing 118 to maintain a desired axial position of the impeller 104 without moving the collar 140 outside a predetermined range of collar positions. The control system 134 may be configured to control the first bearing 118 to drive the collar 140 and the impeller 104 to move in a first direction 130 along the axis 120 and / or to move in a second direction 150 (e.g., a second axial direction) opposite to the first direction 130 along the axis 120. In practice, the control system 134 may control the first bearing 118 based on sensor data received during operation of the compressor 32 (e.g., from the first sensor 146, from the second sensor 158). In some embodiments, the control system 134 may control the first bearing 118 based on additional or alternative data and / or feedback (e.g., received from additional sensors), such as data indicating an operating capacity of the compressor 32, a speed of the compressor 32, a pressure of the working fluid circulated by the compressor 32, a flow rate of the working fluid circulated by the compressor 32, another suitable operating parameter, or any combination thereof. Thus, when the compressor 32 is operating (e.g., the shaft 102 and / or the impeller 104 are rotating), the control system 134 can dynamically adjust the position of the collar 140 and the impeller 104 by controlling the first bearing 118 in real time to maintain the impeller 104 in a desired position. In fact, it should be understood that the control system 134 can be used with any of the embodiments and / or features of the compressor 32 described herein to achieve a desired positioning of the impeller 104 in accordance with the present technology.

[0047] Figure 61 is a cross-sectional side view of an embodiment of a portion of the compressor 32. The compressor 32 includes similar elements and element numbers as described above. The diffuser passage 112 of the compressor 32 can be at least partially defined by the shroud housing portion 132 of the housing 100 and the hub housing portion 202 of the housing 100. The shroud housing portion 132 can be configured to surround a portion of the impeller 104. For example, the impeller 104 can include a shroud 204, which can be integrally formed with and / or connected to the blades 131 of the impeller 104. Specifically, the shroud 204 can include a blade-facing surface 200 connected to the blades 131 of the impeller 104. In practice, the position of the shroud 204 can be fixed relative to the position of the blades 131, so that rotation of the blades 131 causes a corresponding rotation of the shroud 204 and / or axial movement of the blades 131 (e.g., along the axis 120) causes a corresponding axial movement of the shroud 204. The shroud housing portion 132 can surround or surround at least a portion of the shroud 204 and the blades 131. The hub housing portion 202 may be configured to surround another portion of the impeller 104. For example, the impeller 104 may include a hub 206 that may be attached to the shaft 102, and the hub housing portion 202 may surround or enclose at least a portion of the hub 206.

[0048] In the illustrated embodiment, the first sensor 146 (e.g., a proximity sensor) is coupled to the shroud housing portion 132 and extends through the shroud housing portion. For example, the impeller 104 can be positioned within the housing 100 to establish a gap or space 208 between a surface 210 (e.g., an outer surface, an outer shroud surface, a machined surface, a planar surface) of the shroud 204 and the shroud housing portion 132. A hole 212 (e.g., an opening, a passage) can be formed in the shroud housing portion 132 and can extend to the gap 208, and the first sensor 146 can be inserted through the hole 212 and can be exposed to the gap 208. Thus, the first sensor 146 can detect the distance between the surface 210 and the shroud housing portion 132 (e.g., an axial distance along the axis 120). As an example, the first sensor 146 can include a non-contact sensor, such as an eddy current sensor, a capacitive sensor, an optical sensor, an ultrasonic sensor, an inductive sensor, a Hall effect sensor, and / or another suitable type of sensor. The first sensor 146 may be sealingly positioned within the aperture 212, such as by a seal positioned within and / or adjacent to the aperture 212 (e.g., around the first sensor 146). That is, the first sensor 146 and / or the seal may prevent the working fluid from flowing through the aperture 212 between the first sensor 146 and the shroud housing portion 132, thereby maintaining the flow of the working fluid through the impeller 104 and the diffuser passage 112.

[0049] To facilitate detection and / or measurement of gap 208 (e.g., the size of gap 208 extending from shroud housing portion 132 and / or first sensor 146 to surface 210) via first sensor 146, surface 210 may be planar (e.g., flat) and / or may extend along the circumference of impeller 104. In this manner, a more accurate and / or more representative detection of the distance (e.g., an average distance) between surface 210 and shroud housing portion 132 may be made by first sensor 146 during rotation of impeller 104 about axis 120. That is, the distance measured by first sensor 146 based on the detection of surface 210 may better (e.g., more accurately, more reliably) indicate the position of impeller 104 relative to housing 100 (e.g., shroud housing portion 132). For example, such a configuration of surface 210 may reduce detected distance variations caused by variations in the profile (e.g., curvature) of impeller 104 and / or other potential factors that may affect the detection and / or measurement of the distance between surface 210 and shroud housing portion 132, but is independent of the movement of impeller 104 relative to housing 100 (e.g., along axis 120). In this way, the data and / or feedback (e.g., distance data) provided by first sensor 146 to control system 134 may enable control system 134 to operate more appropriately and reliably to adjust the position of impeller 104.

[0050] It should be understood that it may be desirable to align the impeller outlet 114 of the impeller 104 with the diffuser passage 112 to enable the working fluid to flow through the compressor 32 more efficiently. For example, it may be desirable to align the first center axis 216 of the impeller outlet 114 with the second center axis 218 of the diffuser passage 112. Maintaining the alignment between the impeller outlet 114 and the diffuser passage 112 can reduce or mitigate pressure and / or flow losses associated with (e.g., applied to) the working fluid flow, such as due to friction (e.g., between the working fluid and the shroud shell portion 132, between the working fluid and the hub shell portion 202) and / or other undesirable (e.g., turbulent) flow of the working fluid. In this way, maintaining the impeller outlet 114 and the diffuser passage 112 aligned enables the compressor 32 to operate more efficiently. However, during operation of compressor 32 , impeller 104 may deflect (eg, along axis 120 ) such that impeller outlet 114 and diffuser passage 112 become misaligned (eg, first central axis 216 and second central axis 218 are not aligned).

[0051] Thus, according to the present technology, the control system 134 is configured to monitor, adjust and / or otherwise control the axial position of the impeller 104 (e.g., along the axis 120) to align the impeller outlet 114 and the diffuser passage 112. The distance between the surface 210 and the shroud housing portion 132 may indicate the alignment and / or misalignment between the impeller outlet 114 and the diffuser passage 112. The control system 134 may monitor and adjust the axial position of the impeller 104 (e.g., by controlling the first bearing 118, the thrust bearing) to control, adjust and / or maintain the distance between the surface 210 and the shroud housing portion 132, such as maintaining the distance within a predetermined distance value range. The predetermined range of distance values ​​may be associated with a desired positioning of the impeller outlet 114 relative to the diffuser passage 112 (e.g., corresponding to an acceptable or desired alignment of the first center axis 216 and the second center axis 218).

[0052] Although the illustrated first sensor 146 is positioned within the shroud shell portion 132, in additional or alternative embodiments, the first sensor 146 may be positioned within the hub shell portion 202. In such embodiments, the first sensor 146 may be configured to detect a distance (e.g., an axial distance along the axis 120) between a surface (e.g., an axial surface) of the hub 206 and the hub shell portion 202, and the control system 134 may be configured to monitor, adjust, and / or otherwise control the axial position of the impeller 104 (e.g., by controlling the first bearing 118) based on the distance between the surface of the hub 206 and the hub shell portion 202 detected by the first sensor 146.

[0053] It should be noted that in certain existing systems, the diffuser passage 112 may be shaped (e.g., tapered) to accommodate expected misalignment between the impeller outlet 114 and the diffuser passage 112 during operation of the compressor 32. For example, the geometry of the diffuser passage 112 may be selected and / or configured to limit or mitigate losses (e.g., pressure losses, flow losses) of the working fluid during misalignment between the impeller outlet 114 and the diffuser passage 112. In some embodiments, the shroud housing portion 132 may include a first tapered surface 220 (e.g., an inclined surface) that may extend obliquely relative to the second central axis 218 to provide a diffuser inlet 222 having a larger size (e.g., a larger diameter, a larger width, along the axis 120) than the diffuser passage 112 downstream of the diffuser inlet 222 relative to the flow of the working fluid through the diffuser passage 112. Additionally or alternatively, the diffuser inlet 222 may have a larger size (e.g., a larger diameter, a larger width, along the axis 120) than the impeller outlet 114. In additional or alternative embodiments, the hub shell portion 202 may include a second tapered surface 224 that may extend obliquely relative to the second center axis 218 to provide a diffuser inlet 222 having a relatively larger size.

[0054] The tapered geometry of the diffuser passage 112 described above may result in relatively increased losses (e.g., compared to a diffuser passage 112 without such tapered geometry) when the impeller outlet 114 and the diffuser passage 112 are aligned with each other (e.g., during alignment of the first center axis 216 and the second center axis 218). As a result, prior systems may be susceptible to reduced efficiency in the operation of the compressor 32 when the impeller outlet 114 and the diffuser passage 112 are aligned. Controlling (e.g., adjusting) the axial position of the impeller 104 to maintain a general and / or intended alignment between the impeller outlet 114 and the diffuser passage 112 may enable the diffuser passage 112 to be manufactured with a reduced shape (e.g., tapered), i.e., otherwise intended to accommodate an expected misalignment of the impeller outlet 114 and the diffuser passage 112.

[0055] Embodiments of the present disclosure may include diffuser passages 112 having non-tapered or generally linear (e.g., along the first central axis 216) geometry. For example, the shroud housing portion 132 and / or the hub housing portion 202 may have surfaces defining the diffuser passage 112 that extend radially from the impeller outlet 114 relative to the axis 120 (e.g., generally parallel to the first central axis 216 and / or the second central axis 218), rather than having tapered surfaces 220, 224. As an example, the surface of the hub housing portion 202 may extend radially (e.g., completely radially) relative to the axis 120, and the surface of the shroud housing portion 132 may be tapered (e.g., the first tapered surface 220). As another example, the surface of the shroud housing portion 132 may extend radially (e.g., completely radially) relative to the axis 120, and the surface of the hub housing portion 202 may be tapered (e.g., the second tapered surface 224). When the impeller outlet 114 and the diffuser passage 112 are aligned with each other, the radial extension of the surface of the shroud shell portion 132 and / or the hub shell portion 202 can reduce the pressure and / or flow losses of the working fluid, and thus can improve the operating efficiency of the compressor 32 when the impeller outlet 114 and the diffuser passage 112 are aligned. Further, manufacturing the impeller 104 with a diffuser passage 112 having a non-tapered or substantially linear geometry can reduce the costs associated with the manufacture of the impeller 104.

[0056] Figure 7 is a cross-sectional side view of an embodiment of a portion of the compressor 32. The compressor 32 may include certain similar components and component numbers as described above. As shown, the first sensor 146 is positioned within the shroud housing portion 132. Additionally, in the illustrated embodiment, the impeller 104 of the compressor 32 is shown as an unshrouded or partially unshrouded impeller 104 (e.g., without the shroud 204). Therefore, the blades 131 of the impeller 104 are exposed to the shroud housing portion 132. For example, Figure 7 The unshrouded impeller 104 may be lighter than a shrouded impeller, such as Figure 6 The impeller 104 of the shroudless compressor 32 can be made lighter, and thus the weight of the compressor 32 can be reduced. The lighter weight of the shroudless impeller 104 can make the manufacture, installation, transportation, maintenance, etc. of the compressor 32 easier. Additionally or alternatively, the lighter, shroudless impeller 104 can be controlled to rotate at a higher speed than a heavier (e.g., shrouded) impeller. In some embodiments, the shroudless compressor 32 can be made lighter, and the weight of the compressor 32 can be reduced. Figure 6 Compared to the impeller 104 with the shroud 204 , the shroudless impeller 104 may be manufactured at a reduced cost.

[0057] In the mounting configuration of the impeller 104 within the housing 100, a gap or space 250 (e.g., a clearance, a clearance region) may extend between a blade tip or edge 252 (e.g., a distal edge, a distal surface, a blade tip surface) of a blade 131 of the impeller 104 and the shroud shell portion 132 (e.g., an inner surface 260 of the shroud shell portion 132 facing the blade 131). The first sensor 146 may extend through the shroud shell portion 132 to be exposed to the gap 250 and / or the blade tip 252. Thus, the first sensor 146 may be configured to detect, measure, and / or monitor a distance between the blade tip 252 (e.g., a corresponding surface or edge of the blade tip 252) and the shroud shell portion 132. For example, during operation of the impeller 104, the blade 131 may bend, flex, deflect, or otherwise deform (e.g., relative to the hub 206). For example, the blades 131 may pivot or deflect outward (e.g., radially outward) relative to the axis 120 and / or relative to the hub 206. Deflection of the blades 131 in this manner may reduce the size or dimension (e.g., clearance) of the gap 250, which may increase the likelihood of contact between the blades 131 (e.g., blade tips 252) and the shroud shell portion 132. As an example, an increase in the rotational speed of the impeller 104 may exert forces on the blades 131 (e.g., caused by contact between the blades 131 and the working fluid) to cause the blades 131 to bend or deflect and reduce the size of the gap 250 (e.g., reduce the clearance between the blade tips 252 and the shroud shell portion 132). As another example, an increased temperature of the impeller 104 (e.g., caused by friction during operation of the compressor 32, caused by an elevated operating temperature) may cause the blades 131 to thermally expand at least partially in a direction toward the shroud shell portion 132, which may reduce the size or dimension of the gap 250. Indeed, increasing the rotational speed and / or increasing the temperature of the impeller 104 may reduce the size of the gap 250 , thereby reducing the amount of clearance between the blade tips 252 and the shroud shell portion 132 .

[0058] To this end, the control system 134 is configured to adjust the axial position of the impeller 104 (e.g., in real time during operation of the compressor 32) so that the distance between the blade tip 252 and the shroud shell portion 132 is equal to or greater than the predetermined distance, thereby maintaining a desired amount of clearance (e.g., a desired size of the gap 250) between the blade tip 252 and the shroud shell portion 132. For example, the control system 134 may dynamically operate the magnetic bearing components 142, 144 of the first bearing 118 to adjust the position of the collar 140, the shaft 102, and the impeller 104 coupled to each other relative to the shroud shell portion 132 (e.g., along the axis 120), such as based on data and / or feedback. In some embodiments, the control system 134 may operate the first bearing 118 to adjust the position of the impeller 104 based on sensor data (e.g., a sensor from the first sensor 146). The first sensor 146 may detect the size of the distance between the blade tip 252 and the shroud shell portion 132 and provide data or feedback indicating the size of the distance (e.g., the gap 250) to the control system 134. In response, the control system 134 may adjust the operation of the first bearing 118 based on the feedback indicating the magnitude of the distance.

[0059] In some embodiments, the control system 134 may compare the magnitude of the distance detected by the first sensor 146 to a predetermined value or threshold distance value (e.g., a threshold clearance value) or a range of threshold distance values ​​that may be stored in the memory 136, and adjust the position of the impeller 104 based on the comparison (e.g., by controlling the first bearing 118). In some cases, the threshold distance value may be associated, correlated, and / or correspond to a position of the impeller 104 where the impeller outlet 114 and the diffuser passage 112 are aligned with each other. Thus, the present technology may enable the compressor 32 to operate more efficiently (e.g., more efficient flow of the working fluid, reduced pressure drop, etc.). Additionally or alternatively, the threshold distance value (e.g., stored in the memory 136) may be associated, correlated, and / or correspond to a desired magnitude of the distance between the blade tip 252 and the shroud shell portion 132. In some embodiments, control system 134 may control first bearing 118 to maintain a distance between blade tip 252 and shroud housing portion 132 within a predetermined distance value range associated with a desired positioning of impeller 104 within casing 100 (eg, relative to shroud housing portion 132 ).

[0060] Thus, the control system 134 can control the first bearing 118 to control and / or adjust the position of the impeller 104 to prevent potential contact between the blade tip 252 and the shroud housing portion 132. In this manner, the present technology can maintain the structural integrity of the blade tip 252 and the shroud housing portion 132. The present technology can also enable and / or operate a shroudless impeller 104, such as at different rotational speeds of the impeller 104 and / or different operating temperatures associated with the compressor 32.

[0061] In the illustrated embodiment, the shroud housing portion 132 extends along the contour of the impeller 104, such as along the blade tips 252 and / or along the contour defined by the blade tips 252. Thus, the first sensor 146 may be disposed at any suitable location or orientation within the shroud housing portion 132 to extend toward the gap 250, such as at any suitable angle relative to the axis 120. Additionally or alternatively, the first sensor 146 may be positioned in the hub shell portion 202 (e.g., extending within the hub shell portion), and may be configured to monitor the distance between the surface 254 of the hub 206 and the hub shell portion 202 (e.g., along the axis 120). Thus, the control system 134 may be configured to control the axial position of the impeller 104 based on the distance between the surface 254 of the hub 206 and the hub shell portion 202 in a manner similar to that described above.

[0062] Figure 8 1 is a cross-sectional side view of an embodiment of a portion of the compressor 32. In the illustrated embodiment, the first sensor 146 is positioned within the shroud housing portion 132. The impeller 104 also includes a shroud 204. Additionally, the hub 206 of the impeller 104 includes a wall 270 that extends downstream of the impeller outlet 114 relative to the flow of the working fluid through the impeller outlet 114. In other words, the impeller outlet 114 can be generally defined as a port or exhaust port of the impeller 104 extending from a radially outer edge 272 (e.g., a distal end) of the shroud 204 to the wall 270 (e.g., along the axis 120), and the wall 270 can extend downstream of the impeller outlet 114 (e.g., toward and / or along the diffuser passage 112).

[0063] As shown, the first sensor 146 extends through the shroud housing portion 132 and is exposed to the diffuser passage 112. In other words, the first sensor 146 extends through the shroud housing portion 132 and is positioned downstream of the impeller outlet 114 and / or the radial outer edge 272 of the shroud 204 (e.g., relative to the working fluid flow through the impeller 104). Therefore, the first sensor 146 can be positioned on the wall 270 of the detection hub 206 (e.g., along the axis 120). That is, the wall 270 can be exposed to the first sensor 146 and can be detected by the first sensor. For example, the first sensor 146 can detect the distance between the surface 274 of the wall 270 and the shroud housing portion 132. The surface 274 can also be exposed to the working fluid flow. As similarly described above, the distance between the surface 274 of the wall 270 and the shroud housing portion 132 may indicate the position of the impeller 104 relative to the housing 100, such as the alignment between the impeller outlet 114 and the diffuser passage 112 and / or the distance between the impeller 104 (e.g., the blade tip 252, the shroud 204) and the shroud housing portion 132. In a manner similar to that described above, the control system 134 may control the axial position of the impeller 104 (e.g., by controlling the first bearing 118 along the axis 120) to control, adjust and / or maintain the distance between the wall 270 and the shroud housing portion 132 (e.g., the distance between the shroud 204 or blade tip 252 and the shroud housing portion 132). For example, the control system 134 may adjust the position of the impeller 104 so that the distance from the wall 270 (e.g., the surface 274) to the shroud housing portion 132 (e.g., the first sensor 146) is within a predetermined range of distance values ​​associated with the desired positioning of the impeller 104 relative to the housing 100 (e.g., the alignment of the impeller outlet 114 relative to the diffuser passage 112, the alignment of the first center axis 216 and the second center axis 218).

[0064] In additional or alternative embodiments, the first sensor 146 may be configured to detect a different surface of the impeller 104, such as another surface exposed to the flow of the working fluid directed through the impeller 104. For example, the shroud 204 may include a wall (e.g., similar to the wall 270) extending downstream of the impeller outlet 114 relative to the flow of the working fluid through the diffuser passage 112, and the first sensor 146 may be positioned within and extend through the hub shell portion 202. In such embodiments, the first sensor 146 may be configured to detect the distance between the surface of the wall of the shroud 204 and the hub shell portion 202. In such embodiments, the control system 134 may be configured to control the axial position of the impeller 104 (e.g., via control of the first bearing 118) based on the distance between the wall of the shroud 204 and the hub shell portion 202, such as to achieve a desired alignment of the impeller outlet 114 and the diffuser passage 112.

[0065] Fig. 9 1 is a flow chart of an embodiment of a method 300 for adjusting the position of impeller 104. In some embodiments, method 300 may be performed by a single respective component or system, such as by control system 134 (e.g., processing circuit 138). In additional or alternative embodiments, multiple components or systems may perform the steps of method 300. It should also be noted that additional steps may be performed with respect to method 300. Furthermore, certain steps of method 300 as depicted may be performed in different Fig. 9 The order shown was removed, modified and / or executed.

[0066] At block 302, a value of an operating parameter indicative of a position of the impeller 104 may be received. For example, the value of the operating parameter (e.g., data indicative of the value) may be detected by the first sensor 146 and may be received from the first sensor 146 by the control system 134. In some embodiments, the operating parameter may include a distance from the surface 210 of the shroud 204 to the housing 100 (e.g., the shroud housing portion 132, the inner surface 260 of the shroud housing portion 132). In additional or alternative embodiments, the operating parameter may include a distance from the blade tip 252 to the housing 100 (e.g., the shroud housing portion 132, the inner surface 260 of the shroud housing portion 132), a distance from the surface 254 of the hub 206 to the housing 100 (e.g., the hub housing portion 202), a distance from a wall 270 of the impeller 104 and the housing 100 (e.g., the shroud housing portion 132), and / or a distance from any other portion of the impeller 104 to the housing 100. In practice, the operating parameter may indicate the size or dimension of the gap 250 (eg, clearance) between the impeller 104 and the housing 100. The operating parameter may also indicate the alignment of the impeller outlet 114 relative to the diffuser passage 112.

[0067] At box 304, the value of the operating parameter may be compared (e.g., by the control system 134) to a predetermined value, threshold, and / or range of values ​​that may be stored in the memory 136. The predetermined value, threshold, and / or range of values ​​may correspond to a desired position of the impeller 104. For example, the desired position may correspond to a desired alignment between the impeller outlet 114 and the diffuser passage 112 (e.g., alignment of the first center axis 216 and the second center axis 218). In some cases, the range of values ​​may include an upper threshold and a lower threshold (e.g., a predetermined value) that defines or corresponds to a range of positions of the impeller 104 that provide an acceptable alignment of the impeller outlet 114 and the diffuser passage 112. Additionally or alternatively, the desired position may correspond to a desired distance (e.g., a clearance) between the impeller 104 (e.g., the shroud 204, the blade tip 252) and the shroud housing portion 132 (e.g., the inner surface 260).

[0068] In some embodiments, the predetermined value, threshold value, and / or value range may be selected from a plurality of predetermined values, threshold values, and / or value ranges stored in the memory 136. The selection of a particular predetermined value, threshold value, and / or value range (e.g., by the control system 134) may be based on another operating parameter of the compressor 32 present or detected at the time of the comparison, such as a size associated with the impeller 104 (e.g., diameter, size of the impeller outlet 114), an operating capacity of the compressor 32, a rotational speed of the impeller 104, a temperature and / or pressure of the working fluid (e.g., suction temperature and / or pressure), a type of the working fluid, a temperature of the shaft 102, another suitable operating parameter, and / or any combination thereof. In some applications, one or more of the predetermined value, threshold value, and / or value range may be calibrated values ​​corresponding to a desired position of the impeller 104, as described herein.

[0069] At box 306, in response to the comparison of the value (e.g., detected by the first sensor 146) with the predetermined value, threshold, and / or range of values, the position of the impeller 104 within the housing 100 can be adjusted (e.g., by the control system 134). For example, the current transmitted to the magnetic bearing components 142, 144 can be adjusted by the control system 134 to adjust the magnetic force applied to the collar 140, thereby adjusting the axial position of the collar 140 (e.g., along the axis 120) and causing the axial position of the shaft 102 and the impeller 104 to be adjusted accordingly. For example, the axial position of the impeller 104 can be adjusted to maintain the value of the operating parameter (e.g., detected by the first sensor 146) within the value range and / or adjust the value of the operating parameter to within the value range. Similarly, the axial position of the impeller 104 can be adjusted to maintain the value of the operating parameter (e.g., detected by the first sensor 146) approximately equal to the predetermined value or threshold and / or adjust the value of the operating parameter to approach and approximately equal to the predetermined value or threshold. In practice, the method 300 described herein may be implemented to achieve a specific (e.g., desired, minimum, minimum allowable) distance or size of the gap 250 (e.g., clearance) between the impeller 104 and the casing 100. In this manner, the method 300 enables the compressor 32 to operate more efficiently (e.g., reduce losses, improve performance) and / or a more ideal positioning between the impeller 104 and the shroud casing portion 132 under variable operating conditions of the compressor 32.

[0070] It should be noted that the method 300 may be performed repeatedly (e.g., continuously) during operation of the compressor 32. For example, the value of the operating parameter may be received from the first sensor 146 and received by the control system 134 at a desired frequency (e.g., several kilohertz) or interval for comparison with a predetermined value, threshold, and / or range of values. As a result of the comparison, the position of the impeller 104 may be adjusted or maintained accordingly using the presently disclosed techniques. The techniques described herein may also be used to resolve and / or compensate for other variable parameters of the compressor 32, such as variable working fluid conditions, manufacturing tolerances, etc. Further, in some cases, the method 300 may be used to evaluate the performance of the compressor 32 under various operating conditions and / or at different locations of the impeller 104 positioned within the housing 100 (e.g., in real time). For example, the control system 134 may adjust the position of the impeller 104 relative to the shroud housing portion 132, and the control system 134 may receive feedback from other sensors of the HVAC&R system 10 indicating the performance of the compressor 32 and / or the HVAC&R system 10 for evaluating performance changes caused by changes in the position of the impeller 104.

[0071] The present disclosure may provide one or more technical effects useful in the operation of an HVAC&R system. For example, an HVAC&R system may include a compressor having an impeller disposed within a housing. The impeller may rotate to pressurize a working fluid flow and direct the working fluid flow through the impeller to a diffuser passage. During operation of the compressor, the relative positioning between the impeller and the housing may be adjusted. For example, the geometry and / or position of the impeller may change due to thermal growth of a shaft connected to the impeller. As another example, the geometry of the impeller, such as the blades of an impeller without a shroud, may change at different rotational speeds of the impeller. Thus, the distance between the surface of the impeller (e.g., the surface of the shroud of the impeller, the tip of the blade of the impeller, the surface of the wall of the impeller) and the housing may be detected and monitored. The control system may receive data indicating the detected distance, and may compare the detected distance to a specific value or range of values ​​associated with a desired position of the impeller. In response to the comparison, the control system may adjust the position of the impeller so that the detected distance is close to and / or approximately equal to a predetermined value and / or within a predetermined range of values. Specifically, the impeller can be coupled to the shaft, and the position of the shaft can be adjusted (for example, by control of the thrust bearing) to adjust the desired position of the impeller relative to the housing. The adjustment of the position of the impeller can achieve the desired alignment between the outlet of the impeller and the opening of the diffuser channel and / or provide a desired gap between the impeller and the housing. Therefore, a more efficient operation of the compressor can be achieved. The technical effects and technical problems in the specification are examples and are not restrictive. It should be noted that the embodiments described in the specification may have other technical effects and may solve other technical problems.

[0072] Although only certain features and embodiments are shown and described, many modifications and changes may occur to those skilled in the art without materially departing from the novel teachings and advantages of the subject matter recited in the claims, such as changes in size, dimensions, structure, shape and proportion of various elements, parameter values ​​(such as temperature and pressure), mounting arrangements, use of materials, color, orientation, etc. The order or sequence of any process or method steps may be changed or re-sequenced according to alternative embodiments. Therefore, it should be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure.

[0073] Furthermore, in an effort to provide a concise description of exemplary embodiments, not all features of an actual implementation may be described, such as those not relevant to the best mode currently contemplated or those not relevant to enablement. It should be understood that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions may be made. Such development work may be complex and time consuming, but these are routine tasks of design, fabrication, and production for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

[0074] The techniques presented and claimed herein refer to and apply to substantial objects and specific examples of a practical nature that improve the technical field of the invention in a demonstrable manner and are therefore not abstract, intangible, or purely theoretical. In addition, if any claim appended to the end of this specification contains one or more elements expressed as "means for [performing] [the function] ..." or "steps for [performing] [the function] ...", it is expected that such elements will be interpreted in accordance with 35 U.S.C. 112(f). However, for any claim containing elements specified in any other manner, it is intended that such elements will not be interpreted in accordance with 35 U.S.C. 112(f).

Claims

1. A heating, ventilation, air conditioning and refrigeration (HVAC&R) system comprising: A compressor, comprising: case; a shaft disposed within and extending through the housing; and an impeller coupled to the shaft, wherein the shaft is configured to rotate relative to the housing and about an axis to rotate the impeller; and A controller, the controller being configured to: receiving data indicating a distance from a shroud of the impeller to the casing; and The position of the shaft along the axis is adjusted based on a comparison of the distance from the shroud of the impeller to the housing with a predetermined value.

2. The HVAC&R system of claim 1, comprising a thrust bearing coupled to the shaft, wherein the controller is configured to adjust operation of the thrust bearing to adjust the position of the shaft along the axis.

3. The HVAC&R system of claim 2, wherein the thrust bearing is positioned at a first end of the shaft and the impeller is coupled to a second end of the shaft opposite the first end.

4. The HVAC&R system of claim 3, wherein the thrust bearing is a magnetic thrust bearing and the controller is configured to adjust the current supplied to the magnetic thrust bearing to adjust the position of the shaft.

5. The HVAC&R system of claim 1 , comprising a sensor communicatively coupled to the controller, wherein the sensor is configured to detect the distance from the hood to the housing and transmit the data indicative of the distance to the controller, and the controller is configured to compare the distance to the predetermined value.

6. The HVAC&R system of claim 5, wherein the sensor extends through a shroud housing portion of the housing.

7. The HVAC&R system of claim 6, wherein the sensor is configured to detect a surface of the shroud, and the surface is planar and extends along the circumference of the impeller.

8. The HVAC&R system of claim 1, wherein the predetermined value corresponds to an alignment of an outlet of the impeller with a diffuser passage of the housing downstream of the outlet relative to working fluid flow through the compressor.

9. The HVAC&R system of claim 1, wherein the predetermined value corresponds to a clearance between the impeller and a shroud housing portion of the housing.

10. The HVAC&R system of claim 1, wherein the controller includes a memory and the predetermined value is stored on the memory.

11. A heating, ventilation, air conditioning and refrigeration (HVAC&R) system comprising: A controller, the controller being configured to: receiving data indicative of a distance from a shroud of an impeller to a casing of the compressor from a sensor disposed within the compressor; comparing the distance to a predetermined value; and A position of a shaft coupled to the impeller along a rotational axis of the shaft is adjusted based on a comparison of the distance from the shroud of the impeller to the housing with the predetermined value to adjust a position of the impeller relative to the housing.

12. The HVAC&R system of claim 11, wherein the predetermined value corresponds to an alignment of a first central axis of the outlet of the impeller with a second central axis of a diffuser passage of the housing downstream of the outlet relative to working fluid flow through the compressor.

13. The HVAC&R system of claim 11, wherein the controller is configured to adjust operation of a magnetic thrust bearing coupled to the shaft to adjust the position of the shaft.

14. The HVAC&R system of claim 11, wherein the controller is configured to: comparing the distance to a range of values, wherein the range of values ​​includes the predetermined value; and The position of the shaft is adjusted based on a comparison of the distance from the shroud of the impeller to the housing with the range of values ​​to adjust the position of the impeller relative to the housing.

15. The HVAC&R system of claim 11, comprising the sensor, wherein the sensor is configured to extend through a shroud housing portion of the housing.

16. A heating, ventilation, air conditioning and refrigeration (HVAC&R) system comprising: A compressor, comprising: case; a shaft disposed within and extending through the housing; a thrust bearing disposed within the housing and coupled to the shaft; and an impeller disposed within the housing and coupled to the shaft, wherein the impeller includes a plurality of blades and a shroud secured to the plurality of blades; and A controller is configured to control operation of the thrust bearing based on data indicative of a detected distance from the housing to the shroud of the impeller.

17. The HVAC&R system of claim 16, wherein the thrust bearing is positioned at a first end of the shaft and the impeller is coupled to a second end of the shaft opposite the first end.

18. The HVAC&R system of claim 16, comprising a sensor disposed within the compressor, wherein the sensor is communicatively coupled to the controller and the sensor is configured to transmit the data indicative of the detected distance to the controller, and wherein the controller is configured to: comparing the detected distance with a predetermined value; and Operation of the thrust bearing is controlled based on a comparison of the detected distance with the predetermined value.

19. The HVAC&R system of claim 18, wherein the predetermined value corresponds to an alignment of an outlet of the impeller with a diffuser passage of the housing downstream of the outlet relative to working fluid flow through the compressor.

20. The HVAC&R system of claim 16, wherein the shroud includes a planar surface extending around the impeller, and the HVAC&R system includes a sensor disposed within the compressor, wherein the sensor is communicatively coupled to the controller and the sensor is configured to detect the planar surface to measure the detected distance.

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