Mitigating compressor liquid migration and/or floodback using suction temperature sensor and/or liquid level sensor
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Solution Overview
Problem
Conventional compressors in climate control systems are prone to liquid migration and floodback issues, leading to system failures such as main bearing washout, piston failure, and scroll set cracking, which existing solutions like crank case heaters and mechanical regulators are inadequate.
Innovation Solution
Implementing a sensor-enabled contactor/relay/switch control system with external sensors like thermistors and optical level switches to provide adaptive protection and control, using suction line temperature readings and liquid detection to prevent liquid migration and floodback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crank case heaters and mechanical regulators are used, then liquid migration and floodback are addressed to some extent, but system reliability is insufficient and external leakage occurs
Solution Approach 1:
The patent implements feedback control by using suction temperature sensors and liquid level sensors to continuously monitor system conditions and provide real-time feedback to the control system. This enables the system to detect liquid migration and floodback conditions early and respond appropriately, significantly improving reliability compared to conventional open-loop methods like crank case heaters.
Solution Approach 2:
The patent replaces mechanical regulators with an electronic control system that uses sensors (optical level sensors, temperature sensors) and electronic components (relay, control circuit). This substitution eliminates the limitations of mechanical systems, such as external leakage, while providing more precise and adaptive protection against liquid migration and floodback.
2Reliability
If sensor-enabled control system is implemented, then protection against liquid migration and floodback is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated control system. The control circuit combines relay control, sensor signal processing, temperature monitoring, and liquid level detection into one unified device. This consolidation provides comprehensive compressor protection while minimizing the number of separate components, thereby reducing overall system complexity despite the enhanced functionality.
3Measurement precision
If optical level sensors and temperature sensors are used, then liquid detection precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs cost-effective sensor solutions that provide sufficient precision for liquid detection without requiring expensive industrial-grade components. The optical level sensors and temperature sensors selected are designed for cost-effective manufacturing while maintaining adequate measurement precision for compressor protection applications, balancing performance with manufacturing affordability.
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
The system effectively mitigates liquid migration and floodback, offering cost-effective and reliable protection compared to conventional methods, with reduced external leakage and improved reliability.
Implementation Method 1
an optical level sensor inside the compressor that detects liquid refrigerant in the compressor crankcase
Implementation Method 2
a suction temperature sensor coupled directly with the control
Data Source
AI summary
The present disclosure relates to controls and related methods for mitigating liquid (e.g., compressor refrigerant, etc.) migration and/or floodback.