Compressor assembly with liquid sensor
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Solution Overview
Problem
Existing compressor systems lack effective methods to accurately determine the lubricant level in the lubricant sump, which can lead to inefficient operation and potential damage due to either lubricant depletion or overfilling, affecting the reliability and efficiency of climate-control systems.
Innovation Solution
The compressor system incorporates first and second temperature sensors disposed at different vertical positions within the shell, along with a control module that calculates temperature differences and standard deviations to determine the lubricant level, and optionally uses a pressure sensor and heating element to verify the presence of liquid, ensuring accurate detection of the lubricant level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional single-point temperature sensing is used, then the device complexity is low, but the measurement precision of lubricant level is insufficient
Solution Approach 1:
The single temperature sensing point is segmented into multiple temperature sensing points positioned at different vertical locations within the lubricant sump. This segmentation allows the system to detect temperature gradients that correspond to different lubricant levels, thereby improving measurement precision without requiring a single complex sensor.
Solution Approach 2:
The system transitions from one-dimensional single-point temperature measurement to multi-dimensional spatial temperature measurement by positioning sensors at different vertical heights. This dimensional expansion enables the detection of temperature stratification in the lubricant, providing accurate lubricant level information through vertical temperature profile analysis.
2Reliability
If no liquid detection mechanism is implemented, then the device complexity remains low, but the reliability of compressor operation deteriorates due to undetected lubricant depletion
Solution Approach 1:
Temperature serves as an intermediary parameter to indirectly detect lubricant level. Instead of implementing a direct mechanical or electrical liquid level sensor, the system uses temperature measurements from multiple points as a mediator to infer the presence or depletion of lubricant, maintaining reliability while avoiding complex direct detection mechanisms.
Solution Approach 2:
The system replaces potential mechanical liquid level detection mechanisms with a thermal field-based detection approach. By utilizing temperature sensing and analysis of thermal patterns in the lubricant sump, the system achieves reliable lubricant level monitoring without mechanical contact or complex moving parts.
3Measurement precision
If multiple temperature sensors at different positions are installed, then the measurement precision of lubricant level improves, but the device complexity increases
Solution Approach 1:
The multi-point temperature sensing system serves multiple functions: it detects lubricant level, monitors compressor operating temperature, identifies refrigerant flooding conditions, and tracks thermal trends over time. This multi-functionality justifies the added sensor complexity by providing comprehensive diagnostic capabilities from a single sensor array.
Solution Approach 2:
The system implements continuous feedback by repeatedly measuring temperatures at multiple points and comparing the resulting temperature gradients against predetermined thresholds. This feedback mechanism automatically adjusts system operation based on detected lubricant levels and thermal conditions, making the complexity manageable through algorithmic processing rather than mechanical complexity.
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 enables precise monitoring of the lubricant level, preventing operational issues by accurately detecting when the lubricant is below a predetermined level, thus ensuring the compressor operates efficiently and reducing the risk of damage from lubricant depletion or overfilling.
Implementation Method 1
The first temperature sensor is at least partially disposed within the shell at a first position. The second temperature sensor is at least partially disposed within the shell at a second position that is vertically higher than the first position.
Implementation Method 2
the compressor includes a heating element configured to heat liquid within said lubricant sump
Implementation Method 3
The compression mechanism is disposed within the shell and is operable to compress a working fluid
Data Source
AI summary
A compressor may include a shell, a compression mechanism, first and second temperature sensors, and a control module. The shell may define a lubricant sump. The compression mechanism may be disposed within the shell and may be operable to compress a working fluid. The first temperature sensor may be at least partially disposed within the shell at a first position. The second temperature sensor may be at least partially disposed within the shell at a second position that is vertically higher than the first position. The control module may be in communication with the first and second temperature sensors and the pressure sensor and may determine whether a liquid level in the lubricant sump is below a predetermined level based on data received from the first and second temperature sensors.