Controller for a cooling unit compressor, system and use
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Solution Overview
Problem
Existing cooling unit compressors for ultra-low temperature applications face inefficiencies in energy consumption, mechanical issues, and compatibility with varying mains voltages and frequencies, leading to high electrical power draw and complex control systems.
Innovation Solution
A controller using voltage converter means to adjust AC voltage levels based on temperature thresholds and mains voltage detection, allowing flexible operation without speed control, ensuring efficient energy use and compliance with maximum current limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If motors are switched on and off by thermostat or sensor control to maintain target temperature, then the target temperature can be maintained, but mechanical issues arise and vibration and noise generation are promoted
Solution Approach 1:
The patent applies variable-speed control to the compressor motors, allowing the motor speed to be continuously adjusted rather than simply switched on and off. This dynamic control enables smooth transitions in cooling capacity while maintaining target temperature, eliminating the mechanical stress and vibration associated with frequent start-stop operations.
Solution Approach 2:
The patent changes the operating parameters of the compressor motors by adjusting motor speed across a continuous range. By varying the speed parameter instead of binary on/off states, the system maintains temperature control while avoiding the mechanical reliability issues and vibration problems caused by frequent switching.
2Use of energy by moving object
If variable-speed control of compressor motors is implemented to reduce load after down-cooling, then energy efficiency is improved, but complexity of control and motor structure is significantly increased
Solution Approach 1:
The patent employs a universal controller that can adapt to different mains voltage systems and frequency ranges without requiring specifically adjusted asynchronous motors for each region. This multi-functional controller handles voltage conversion and motor control in a unified system, reducing overall complexity compared to having region-specific motor designs.
Solution Approach 2:
The patent achieves energy efficiency by changing the motor speed parameter through a unified control system that adjusts voltage and frequency output to the motors. This approach maintains relatively simple motor structures while using the controller to dynamically adjust operating parameters for optimal efficiency at different load conditions.
3Adaptability or versatility
If specifically adjusted asynchronous motors are used for different mains voltage systems, then regional compatibility is achieved, but adaptability to different mains voltages and frequencies is reduced
Solution Approach 1:
The patent implements a universal controller that can operate with different mains voltage systems and frequency ranges (typically 100V-240V, 50Hz-60Hz) without requiring region-specific motor designs. The controller adapts its input parameters to match the local mains configuration while providing consistent output control to the compressors.
Solution Approach 2:
The controller acts as an intermediary between the mains power supply and the compressor motors. It receives power from various mains configurations and converts/adjusts it to appropriate levels for motor operation, eliminating the need for specifically adjusted motors for different regions while maintaining full compatibility.
4Speed
If cooling circuits are configured for maximum load, then down-cooling performance is optimized, but energy consumption is high during stationary cooling mode
Solution Approach 1:
The patent uses dynamic speed control of the compressor motors, allowing the system to operate at maximum speed during down-cooling phases and then transition to reduced speeds during stationary cooling mode. This dynamic adjustment optimizes both down-cooling performance and energy efficiency during maintenance phases.
Solution Approach 2:
The patent implements periodic adjustment of motor speeds based on cooling phase requirements. During down-cooling, motors operate at high speed; once target temperature is reached, the controller reduces speed to maintain temperature with minimal energy consumption, creating a periodic cycle of high and low power states.
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
Significantly reduces electrical power consumption by up to 15% and enables universal connectivity to different mains voltage environments without complex speed control or additional sensor signals, maintaining efficient operation at ultra-low temperatures.
Implementation Method 1
A controller using voltage converter means to adjust AC voltage levels based on temperature thresholds and mains voltage detection
Implementation Method 2
controller for a cooling unit compressor having at least one two-phase AC asynchronous motor
Data Source
AI summary
The invention relates to a control apparatus for a refrigerator compressor having at least one two-phase AC asynchronous motor (K1, K2), having mains connection means (10) for connection to a preferably public voltage supply network which nominally provides a mains AC voltage of between 85 V and 264 V, in particular between 100 V and 230 V, first voltage converter means (14) which are connected downstream of the mains connection means and are intended to generate an intermediate voltage, in particular an intermediate DC voltage, from the mains AC voltage, second voltage converter means (16-1, 16-2) which are connected downstream of the first voltage converter means and are intended to generate an output signal which is independent of a level and a mains frequency of the mains AC voltage, in particular has a constant voltage and/or frequency in periods, and is intended to control the refrigerator compressor with an AC voltage of a plurality of differently predefinable voltage levels, wherein the mains connection means are assigned voltage detector means (12) for capturing the mains AC voltage, the detector output signal from which can be evaluated by the second voltage converter means or control means (24) assigned to the latter for the purpose of generating a mains-voltage-dependent maximum value for a current of the output signal.