Compressor Data Module for Multi-Compressor Fault Detection
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Solution Overview
Problem
Conventional protection systems for refrigeration compressors are complex, costly, and limited to single compressor and controller configurations, unable to efficiently diagnose and control multiple compressors due to reliance on discrete temperature and pressure sensors, which restricts their adaptability and scalability.
Innovation Solution
A protection and control system incorporating a data module that utilizes a series of sensors and non-measured operating parameters to diagnose and control refrigeration systems, providing flexible compatibility with various control modules by deriving multiple levels of data, including sensor data and processed parameters, to enhance fault detection and system efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional protection systems use multiple temperature and pressure sensors to detect operating parameters, then fault detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a data module as an intermediary component that receives data from multiple sensors and processes it to generate derived operating parameters. This mediator consolidates the complexity of handling multiple sensor inputs, providing a unified interface for fault detection while maintaining the benefits of comprehensive monitoring.
Solution Approach 2:
The patent replaces direct mechanical/electrical protection systems with a data-processing-based approach. Instead of using multiple discrete sensors directly controlling protection functions, the system uses a centralized data module that processes sensor data and generates control signals, substituting complex mechanical protection circuits with software-based parameter derivation and analysis.
2Adaptability or versatility
If conventional protection systems are designed for single compressor and controller configurations, then system simplicity is maintained, but adaptability and scalability are reduced
Solution Approach 1:
The data module is designed with universal functionality to work with multiple compressor and controller configurations. It provides standardized data interfaces and derived parameters that can be applied across different system architectures, enabling the same protection system to adapt to various configurations without requiring redesign.
Solution Approach 2:
The protection system is segmented into modular components, with the data module as a独立 functional unit that can be independently configured and deployed. This segmentation allows the system to be scaled and adapted to different configurations by adding or removing compressor units while maintaining the core protection functionality through standardized data interfaces.
3Speed
If discrete switches are used to interrupt power when thresholds are exceeded, then response speed is improved, but measurement precision and system efficiency are reduced
Solution Approach 1:
The system implements feedback through the data module that continuously monitors sensor data and derived operating parameters, comparing them against threshold values. When thresholds are exceeded, the system provides feedback signals to interrupt power supply, maintaining fast response while enabling precise threshold evaluation through processed parameter analysis rather than direct switch activation.
Solution Approach 2:
The data module performs preliminary processing of sensor data to derive accurate operating parameters before triggering protection actions. This preliminary action ensures that threshold comparisons are based on precisely calculated parameters rather than raw sensor signals, improving measurement precision while maintaining rapid response through pre-computed readiness for threshold evaluation.
Data Source
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AI summary
A compressor includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a processor and a memory. The compressor controller includes a processor and a memory. The data module receives sensed data, stores sensed data in the memory, and communicates sensed data to the compressor controller. The compressor controller controls a capacity of the compressor based on the sensed data and is operable to communicate with a system controller of a refrigeration system.