Refrigerator Compressor Control Using Phase Currents for Piston Position

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Solution Overview

Problem

Existing household refrigeration devices with refrigerant circuits face inefficiencies in compressor operation, particularly in controlling the position of the piston within the compressor chamber, which affects cooling performance and energy consumption.

Innovation Solution

A method and device utilizing a three-phase synchronous motor with a measuring device to determine the actual speed and position of the piston, processing electrical phase currents to optimize compressor operation, including field-oriented control for improved torque management and precise position detection, allowing for efficient compression and cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the compressor is controlled without precise piston position detection, then the device complexity is reduced, but the cooling performance and energy efficiency deteriorate

Engineering Contradiction:
Improvepiston position detection precisionVSAvoidcontrol system complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces mechanical position detection systems with an electrical measurement approach. The measuring device determines piston position indirectly by measuring electrical phase currents of the three-phase synchronous motor and processing these signals to derive position information. This substitution eliminates complex mechanical sensors while achieving precise position detection through electrical signal analysis.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary measurement approach where electrical phase currents serve as the mediator between the motor operation and piston position. Instead of directly measuring mechanical position, the system measures electrical parameters (phase currents) and processes them to determine position, using the electrical domain as an intermediary to avoid direct mechanical measurement complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Use of energy by moving object

If the piston position is not accurately determined, then the device complexity is reduced, but the energy consumption increases due to inefficient compressor operation

Engineering Contradiction:
Improvecompressor energy consumptionVSAvoidpiston position measurement precision
Core Design Contradiction:
Use of energy by moving objectVSMeasurement precision

Solution Approach 1:

The patent implements a feedback control system where the measured electrical phase currents are continuously processed to determine actual piston position. This position information feeds back to the control device, enabling real-time adjustment of compressor operation to optimize energy efficiency. The feedback loop ensures the compressor operates at optimal points by continuously monitoring and responding to actual piston position.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent replaces energy-intensive mechanical position sensing systems with an electrical measurement and processing approach. By using electrical phase current measurements and signal processing to determine position, the system achieves precise position detection with lower energy consumption compared to traditional mechanical sensors and actuators.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If a three-phase synchronous motor with pole pair number greater than 1 is used, then the manufacturing precision of piston position detection is improved, but the device complexity increases

Engineering Contradiction:
Improverotor angular position detection precisionVSAvoidmotor control complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces mechanical rotor position sensors with an electrical measurement system that determines angular position from phase currents. The three-phase synchronous motor's electrical parameters are measured and processed to derive rotor position information, substituting mechanical sensing with electrical signal analysis to achieve precise position detection without additional mechanical components.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent makes the motor's electrical system serve dual purposes: both driving the compressor and providing position detection. The same three-phase synchronous motor that drives the compressor also generates the electrical signals (phase currents) that are measured and processed to determine rotor position. This self-service approach eliminates the need for separate position sensing systems.

Inventive Principle:
Principle #25Self-service

4Productivity

If the compressor operates without optimized control based on actual speed and position, then the ease of operation is improved, but the cooling performance deteriorates

Engineering Contradiction:
Improvecooling performanceVSAvoidcompressor control complexity
Core Design Contradiction:
ProductivityVSEase of operation

Solution Approach 1:

The patent implements feedback control where the control device receives actual speed and position information from the measuring device and adjusts motor operation accordingly. This feedback enables the compressor to operate at optimal points for maximum cooling efficiency, automatically adapting to changing conditions without manual intervention.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent performs preliminary determination of actual speed and position using the measuring device before making control adjustments. By continuously measuring and processing electrical phase currents to establish current operating conditions, the system prepares the necessary information in advance for optimal control decisions, enabling proactive optimization rather than reactive correction.

Inventive Principle:
Principle #10Preliminary action

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

Enhances compressor control behavior, reduces energy consumption, and improves cooling performance by accurately determining piston position and torque, leading to smoother operation and reduced stop noise.

Implementation Method 1

the three-phase synchronous motor (36) generates a torque (M) dependent on the position of the piston (34), which torque becomes maximum close to or at the top dead center

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a measuring device (42) by means of which electrical phase currents (i1,2,3) of the three-phase synchronous motor (36) are measured and an actual speed of the three-phase synchronous motor (36) is determined by the measuring device (42) comparing the determined actual speed and the measured electrical phase currents (i1,2,3)

Methodology Applied
Scientific EffectElectrical current measurement and processing: Ohmmeter

Implementation Method 3

the piston is able to reduce a volume enclosed by the compressor chamber and the piston by means of the three-phase synchronous motor in order to compress the coolant

Methodology Applied
Scientific EffectMechanical compression: Compression

Data Source

PatentEP3338038B1Domestic refrigeration appliance with a coolant circuit, and method for operating a domestic refrigeration appliance with a coolant circuit
Publication Date: 2024.10.09 BSH HAUSGERATE GMBH
  • EP3338038B1 patent drawingFigure 1~2
  • EP3338038B1 patent drawingFigure 3~4
  • EP3338038B1 patent drawingFigure 5

AI summary

The invention relates to a domestic refrigeration appliance (1) and to a method for operating a domestic refrigeration appliance (1). The domestic refrigeration appliance (1) comprises a heat-insulated basic body (10) with a coolable inner container (2), which bounds a coolable interior (3) provided for storing foods, also comprises a refrigerant circuit (20) which has a coolant and a compressor (21) and is provided for cooling the coolable interior (3), and further comprises an electronic control device (8) and an electric drive (40), which has a three-phase AC synchronous motor (36) and an actuator which is designed in particular in the form of an inverter (41) and is intended for activating the three-phase AC synchronous motor (36). The compressor (21) comprises a compressor chamber (31) with an inlet (32) and with an outlet (33), also comprises a piston (34), which is mounted in a displaceable manner within the compressor chamber (31), and further comprises a crankshaft (35) and the three-phase AC synchronous motor (36). The three-phase AC synchronous motor (36) has a number P of pole pairs greater than 1, a stator (37) and a rotor (38), which is mounted in a rotatable manner in relation to the stator (37) and is coupled to the piston (34) via the crankshaft (35), and therefore, during operation of the compressor (21), the piston (34) is able, by means of the three-phase AC synchronous motor (36), to reduce the size of a volume (39) enclosed by the compressor chamber (31) and the piston (34) so that the coolant is compressed.