Compressor crankcase heating control systems and methods
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Solution Overview
Problem
Compressors face inefficiencies and energy wastage due to continuous crankcase heating, which is not optimized by ambient and compressor temperatures, leading to increased bearing wear and decreased performance during cold starts and liquid flood-back issues.
Innovation Solution
A crankcase heating control system that selectively applies power to the heater based on compressor, ambient temperatures, and current date/time, disabling the heater when not necessary to reduce energy consumption and prevent unnecessary heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous crankcase heating is applied, then lubricant temperature is maintained, but energy consumption increases and bearing wear increases due to unnecessary heating
Solution Approach 1:
The patent applies dynamics by transitioning from continuous static heating to dynamic conditional heating. The control system dynamically adjusts heater operation based on real-time temperature sensor feedback, compressor runtime status, and ambient conditions, enabling the heating system to adapt its behavior to actual operational needs rather than running continuously
Solution Approach 2:
The patent implements feedback through temperature sensors that continuously monitor crankcase and ambient temperatures, feeding this data back to the control system. The control system uses this feedback to determine when heating is actually needed, creating a closed-loop control system that prevents both overheating and unnecessary energy consumption
2Reliability
If continuous crankcase heating is applied, then lubricant viscosity is controlled, but performance decreases due to inefficient operation and liquid flood-back issues
Solution Approach 1:
The patent applies preliminary action by initiating crankcase heating during specific pre-determined conditions such as extended compressor off-periods, cold ambient temperatures, or after liquid refrigerant migration events. This proactive heating approach prepares the lubricant for optimal viscosity before the compressor starts, preventing cold-start damage and liquid flood-back issues
Solution Approach 2:
The patent implements parameter changes by monitoring and responding to variations in temperature parameters, compressor runtime parameters, and environmental conditions. The control system adjusts heating parameters dynamically based on these changing conditions, optimizing lubricant viscosity for each specific operational scenario rather than maintaining constant heating
3Use of energy by moving object
If crankcase heating is disabled completely, then energy consumption is reduced, but bearing wear increases due to cold starts and insufficient lubrication
Solution Approach 1:
The patent applies self-service by implementing a control system that automatically monitors temperature conditions and activates heating only when genuinely needed. The system serves itself by making intelligent decisions based on sensor feedback, eliminating the need for manual intervention while ensuring bearing protection is provided precisely when required
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances compressor performance by optimizing heating, reducing energy usage, and preventing damage from cold starts and liquid migration, thereby improving efficiency and extending compressor lifespan.
Implementation Method 1
a heater of a crankcase of the compressor
Data Source
AI summary
A crankcase heating control system for a heat pump system includes a data receiving module and a power control module. The data receiving module is configured to receive: data indicative of a temperature of a compressor of the heat pump system; and data indicative of an ambient temperature. The power control module is configured to: selectively apply power to a heater of a crankcase of the compressor; and disable the heater when all of: a period since the compressor was last turned is greater than a predetermined period; the ambient temperature is less than a predetermined temperature; and the temperature of the compressor is less than the predetermined temperature.