Compressor Data Module with Dual-Processor Fault Verification
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Solution Overview
Problem
Conventional compressor protection systems are complex and costly, limited to single compressor and controller configurations, and cannot efficiently diagnose and manage faults across multiple control modules, leading to inefficiencies and potential damage in refrigeration systems.
Innovation Solution
A data module with a processor and memory that receives and processes sensor data to determine compressor and refrigeration system diagnoses, communicating with a compressor controller to verify and manage fault conditions, allowing for flexible integration with various control modules and systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional protection systems use multiple temperature and pressure sensors to detect operating parameters, then the compressor protection capability is improved, but the system complexity and cost increase
Solution Approach 1:
The patent combines multiple temperature and pressure sensors into a single integrated sensor that can detect multiple operating parameters simultaneously. This reduces the number of separate sensors needed while maintaining comprehensive monitoring capability, thereby lowering system complexity and cost without compromising protection capability
Solution Approach 2:
The integrated sensor is designed to perform multiple functions - detecting both temperature and pressure parameters within the compressor system. This multi-functional approach eliminates the need for separate dedicated sensors for each parameter, simplifying the overall system architecture
2Device complexity
If conventional protection systems are tied to a single compressor and controller, then the system simplicity is maintained, but the adaptability to multiple control modules is reduced
Solution Approach 1:
The protection system is designed with universal communication interfaces and standardized data protocols that enable it to work with multiple different control modules and compressor types. The system can adapt to various configurations without requiring custom integration for each setup, thus providing versatility while maintaining operational simplicity through standardized connections
3Speed
If conventional protection systems directly control the compressor, then the control responsiveness is improved, but the ability to diagnose faults across multiple systems is reduced
Solution Approach 1:
The system separates the direct control function from the diagnostic function. While the protection system maintains rapid direct control capabilities for immediate compressor protection, it also incorporates comprehensive data collection and analysis features that enable cross-system fault diagnosis. This segmentation allows both rapid response and extensive diagnostic capabilities to coexist
Data Source
AI summary
A compressor is provided and includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a data module processor and a data module memory. The compressor controller includes a controller processor and a controller memory distinct from the data module processor and the data module memory. The data module receives sensed data, stores the sensed data in the data module memory, determines a first diagnosis of the compressor based on the sensed data, and communicates the sensed data and the first diagnosis to the compressor controller. The compressor controller determines a second diagnosis of the compressor based on the sensed data and verifies the first diagnosis by comparing the first diagnosis to the second diagnosis.