System and method of adjusting compressor modulation range based on balance point detection of the conditioned space
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Solution Overview
Problem
Climate-control systems with fixed compressors face inefficiencies due to short cycling and high auxiliary heat usage, particularly in varying ambient temperatures, which affects energy efficiency and comfort.
Innovation Solution
A climate-control system with a variable-capacity compressor and a control module that adjusts compressor stages and lockout thresholds based on outdoor ambient temperature and cycle run times, using a strike counter system to modify lockout thresholds and enable auxiliary heating strategically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a fixed-capacity compressor is used in a climate-control system, then the system structure is simpler and manufacturing cost is lower, but the system experiences short cycling and high auxiliary heat usage leading to reduced energy efficiency
Solution Approach 1:
The patent implements a variable-capacity compressor that dynamically adjusts its operating capacity based on outdoor ambient temperature conditions. The compressor can operate in multiple stages (e.g., high stage, low stage, or off) rather than running continuously at fixed capacity, allowing the system to match heating/cooling demand more precisely and reduce short cycling
Solution Approach 2:
The control module modifies operational parameters including lockout thresholds and compressor stage selection based on outdoor temperature. By changing these parameters dynamically, the system optimizes energy efficiency across varying temperature conditions without requiring excessive complexity
2Reliability
If the compressor lockout threshold is set conservatively to prevent short cycling, then compressor reliability improves, but auxiliary heat usage increases reducing energy efficiency
Solution Approach 1:
The control module dynamically adjusts the lockout threshold parameter based on outdoor ambient temperature. When temperatures are moderate, the lockout threshold is set to allow compressor operation. When temperatures extremes are detected, the threshold is adjusted to prevent short cycling. This dynamic parameter adjustment resolves the contradiction by adapting the lockout behavior to current conditions rather than using a fixed conservative threshold
Solution Approach 2:
The system transitions from static lockout threshold settings to dynamic adjustment based on real-time temperature conditions and compressor performance history, allowing the lockout behavior to adapt to varying operational contexts
3Speed
If the compressor runs continuously at high capacity to meet heating/cooling demand, then the system responds faster to temperature changes, but energy consumption increases and short cycling is more likely
Solution Approach 1:
The variable-capacity compressor dynamically selects between high stage, low stage, and off states based on outdoor temperature and heating/cooling demand. This allows the system to respond appropriately to temperature changes without unnecessarily running at high capacity when lower capacity suffices, thereby reducing energy consumption while maintaining adequate response speed
Solution Approach 2:
The system applies partial action by operating the compressor at reduced capacity (low stage) when full high-capacity operation is not needed to meet the heating or cooling load. This prevents excessive energy consumption while still maintaining system responsiveness
Data Source
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AI summary
A climate-control system includes a variable-capacity compressor, an outdoor ambient temperature sensor, a user-controlled device, and a control module. The outdoor ambient temperature sensor indicates a temperature of outdoor ambient air. The user-controlled device provides a demand signal indicating a demand for at least one of heating and cooling. The control module commands a compressor stage and a stage run time based on the temperature from the outdoor ambient temperature sensor and the demand signal. The control module also modifies a lockout threshold based on a cycle run time, where the cycle run time is an actual run time for the compressor to meet a setpoint temperature.