Screw Compressor Torque Profiling for Stable Refrigeration Drive

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Solution Overview

Problem

Screw compressors in refrigeration systems face challenges in efficiently managing torque profiles to minimize non-productive radial and axial forces, leading to pulsating torque and dynamic transmission of forces, which affect stability and efficiency.

Innovation Solution

A method is introduced to control screw compressors by receiving status signals, determining operating points, and selecting torque profiles based on these signals to drive the compressor, using a controller and electric motor system to adjust torque delivery, thereby reducing non-productive forces and maintaining stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional torque delivery is used in screw compressors, then the compressor can operate continuously, but non-productive radial and axial forces cause pulsating torque and dynamic transmission of forces, reducing stability and efficiency

Engineering Contradiction:
Improveoperational stabilityVSAvoidenergy efficiency
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies dynamics by transitioning from conventional static torque delivery to dynamic torque control. The controller continuously adjusts torque delivery based on real-time operating conditions, allowing the system to adapt to varying loads and minimize non-productive forces. This dynamic approach optimizes the balance between radial and axial forces throughout the compression cycle, reducing pulsating torque while maintaining operational stability across different operating points.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying torque delivery parameters based on operating conditions. The controller varies torque magnitude and timing to optimize compressor performance at different operating points. By changing torque parameters dynamically, the system minimizes harmful radial and axial forces while maintaining efficient operation, directly addressing the contradiction between stability and energy efficiency.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If torque profiles are optimized to reduce non-productive forces, then stability improves, but the complexity of control increases

Engineering Contradiction:
Improveoperational stabilityVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies feedback by implementing a closed-loop control system that continuously monitors compressor operating conditions and adjusts torque delivery accordingly. The controller receives feedback on actual performance and compares it with target values, automatically modifying torque parameters to maintain optimal operation. This feedback mechanism enables sophisticated torque profiling without requiring overly complex control architecture, as the system self-regulates based on real-time conditions.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent implements self-service through an automated control system that independently manages torque optimization without external intervention. The controller automatically determines optimal torque profiles based on operating conditions, eliminating the need for manual adjustment or complex external control systems. This self-service capability achieves high operational stability while keeping the control system relatively simple and autonomous.

Inventive Principle:
Principle #25Self-service

3Loss of energy

If dynamic torque control is implemented, then pulsating torque is reduced, but the extent of automation increases

Engineering Contradiction:
Improveenergy efficiencyVSAvoidcontrol automation level
Core Design Contradiction:
Loss of energyVSExtent of automation

Solution Approach 1:

The patent applies mechanics substitution by replacing conventional mechanical torque delivery with electronically controlled torque management. Instead of relying on fixed mechanical coupling, the system uses an electric motor with electronic control to deliver torque. This substitution enables dynamic adjustment of torque parameters through software control, significantly reducing pulsating torque and improving energy efficiency while maintaining a relatively simple physical architecture.

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

Solution Approach 2:

The patent implements parameter changes by using electronic control to dynamically modify torque delivery parameters. The controller adjusts current magnitude, frequency, and phase to optimize torque output in real-time. This electronic parameter control achieves superior energy efficiency compared to fixed mechanical systems, with the added benefit that the automation is implemented through software rather than complex mechanical mechanisms, keeping the physical system relatively simple.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS8875530B2Screw compressor drive control
Publication Date: 2014.11.04 TRANE INTERNATIONAL INC
  • US8875530B2 patent drawing
  • US8875530B2 patent drawing
  • US8875530B2 patent drawing

AI summary

An embodiment of method used to control operation of a screw compressor of a refrigeration system may include receiving status signals regarding operation of the screw compressor of the refrigeration system. The method may further include determining an operating point of the screw compressor based upon the received status signals, and selecting a torque profile for the screw compressor based upon the operating point. The method may also include driving the screw compressor per the selected torque profile. Refrigeration systems and compressor systems suitable for implementing the method are also presented.