Compressor Condition Detection via Genset Parameter Patterns
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Solution Overview
Problem
Existing transport refrigeration systems (TRS) face inefficiencies in fuel consumption and noise production due to gensets operating at constant speeds, which do not adapt to changing compressor conditions, leading to suboptimal operation and reduced service life.
Innovation Solution
A method to detect compressor operation conditions by analyzing genset operation parameter patterns, such as RPM, horsepower, torque, and fuel consumption, to control the prime mover's speed, switching from high to low speed when the temperature setpoint is reached, thereby optimizing fuel efficiency and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the genset operates at a constant high speed to ensure sufficient power supply to the compressor, then the power supply reliability is improved, but the fuel consumption increases and noise is generated
Solution Approach 1:
The genset operates at variable speeds rather than constant speed. The controller adjusts the prime mover speed dynamically based on compressor conditions - operating at high speed when the compressor requires full power (below temperature setpoint) and at low speed when the compressor is in load/unload cycle (at temperature setpoint), thus reducing fuel consumption while maintaining power supply reliability
Solution Approach 2:
The operational parameters of the genset (speed, power output) are changed based on the operational state of the compressor. By detecting patterns in genset operation parameters such as RPM and power output, the system identifies when the compressor reaches temperature setpoint and adjusts genset parameters accordingly to optimize fuel efficiency
2Reliability
If the genset operates at a constant high speed to ensure sufficient power supply to the compressor, then the power supply reliability is improved, but the noise production increases
Solution Approach 1:
The genset operates at variable speeds rather than constant speed. The controller adjusts the prime mover speed dynamically based on compressor conditions - operating at high speed when the compressor requires full power (below temperature setpoint) and at low speed when the compressor is in load/unload cycle (at temperature setpoint), thus reducing noise generation while maintaining power supply reliability
3Use of energy by moving object
If the genset operates at variable speeds to optimize fuel efficiency, then the fuel consumption is reduced, but the complexity of speed control increases
Solution Approach 1:
The controller continuously monitors genset operation parameters (RPM, power output) and compares them against predefined patterns that indicate compressor operational states. When the pattern matching detects that the compressor has reached temperature setpoint, the controller provides feedback to adjust the prime mover speed to low speed, creating a closed-loop control system that automates the variable speed operation
Solution Approach 2:
The system uses the genset's own operational parameter patterns as the basis for control decisions. By analyzing patterns in its own RPM and power output data, the genset controller can autonomously determine when to switch between high and low speeds without requiring external input or complex external control systems
Data Source
AI summary
Embodiments to help detect operation conditions of a compressor of a TRU in real time by a genset are disclosed. The operation conditions of the compressor can be determined by monitoring a parameter pattern of the genset, such as value changes of a horsepower, a torque, an exhaust temperature, fuel consumption and/or a RPM of a prime mover of the genset, or a current drawn from a generator of the genset, over a period of time. In one embodiment, when a scroll compressor is used in the TRU, the scroll compressor may start a periodical load/unload duty cycle when the TRU reaches its setpoint. The periodical load/unload duty cycle of the scroll compressor can be detected based on a corresponding fluctuation pattern in genset parameters. When this periodically fluctuating pattern of ECU parameters and/or current drawn is detected, the prime mover can be switched to a low operation speed.