Method for controlling an expansion device of a vapor compression system during start-up using rates of change of an evaporator inlet and outlet temperature

Abstract

A method for controlling a vapor compression system during start-up is disclosed. The rate of change, ΔT.sub.1, of the temperature of refrigerant entering the evaporator, and the rate of change, ΔT.sub.2, of the temperature of refrigerant leaving the evaporator are compared. Based on the comparing step, a refrigerant filling state of the evaporator is determined. The opening degree of the expansion device is then controlled according to a first control strategy in the case that it is determined that the evaporator is full or almost full, and according to a second control strategy in the case that it is determined that the evaporator is not full. Thereby it is ensured that a maximum filling degree of the evaporator is quickly reached, without risking that liquid refrigerant passes through the evaporator.

Claims

1. A method for controlling a vapour compression system during start-up, the vapour compression system comprising a compressor, a condenser, an expansion device having a variable opening degree, and an evaporator arranged along a refrigerant path, the method comprising the steps of: starting operation of the vapour compression system, monitoring a first temperature, T.sub.1, of refrigerant entering the evaporator, monitoring a second temperature, T.sub.2, of refrigerant leaving the evaporator, deriving a first rate of change, ΔT.sub.1, of the first temperature, and a second rate of change, ΔT.sub.2, of the second temperature, comparing the first rate of change, ΔT.sub.1, to the second rate of change, ΔT.sub.2, based on the comparing step, determining whether the evaporator is full or is not full, and controlling an opening degree of the expansion device according to a first control strategy if the evaporator is determined to be full or controlling the opening degree of the expansion device according to a second control strategy if the evaporator is determined to be not full.

2. The method according to claim 1, wherein the first control strategy comprises the step of gradually decreasing the opening degree of the expansion device.

3. The method according to claim 2, further comprising the steps of: monitoring a difference between the first temperature, T.sub.1, and the second temperature, T.sub.2, during the step of gradually decreasing the opening degree of the expansion device, and discontinuing decreasing the opening degree of the expansion device in the case that the difference between the first temperature, T.sub.1, and the second temperature, T.sub.2, exceeds a predetermined threshold value.

4. The method according to claim 1, wherein the second control strategy comprises the step of gradually increasing the opening degree of the expansion device.

5. The method according to claim 4, further comprising the steps of: monitoring the second rate of change, ΔT.sub.2, during the step of gradually increasing the opening degree of the expansion device, and discontinuing increasing the opening degree of the expansion device in the case that the numerical value of the second rate of change, ΔT.sub.2, exceeds a predetermined threshold value.

6. The method according to claim 5, further comprising the step of: monitoring the second temperature, T.sub.2, during the step of gradually increasing the opening degree of the expansion device, wherein the step of discontinuing increasing the opening degree is only performed if the second temperature has decreased by a predetermined amount as compared to an initial temperature value of the second temperature.

7. The method according to claim 5, further comprising the step of decreasing the opening degree of the expansion device to an initial opening degree after the step of discontinuing increasing the opening degree of the expansion device.

8. The method according to claim 1, wherein the step of monitoring the first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring the second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

9. The method according to claim 8, further comprising the step of calibrating the first temperature sensor.

10. The method according to claim 9, wherein the step of calibrating the first temperature sensor is performed during start-up of the vapour compression system.

11. The method according to claim 1, wherein the step of starting operation of the vapour compression system comprises starting operation of the compressor.

12. The method according to claim 2, wherein the second control strategy comprises the step of gradually increasing the opening degree of the expansion device.

13. The method according to claim 3, wherein the second control strategy comprises the step of gradually increasing the opening degree of the expansion device.

14. The method according to claim 6, further comprising the step of decreasing the opening degree of the expansion device to an initial opening degree after the step of discontinuing increasing the opening degree of the expansion device.

15. The method according to claim 2, wherein the step of monitoring a first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring a second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

16. The method according to claim 3, wherein the step of monitoring a first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring a second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

17. The method according to claim 4, wherein the step of monitoring a first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring a second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

18. The method according to claim 5, wherein the step of monitoring a first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring a second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

19. The method according to claim 6, wherein the step of monitoring a first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring a second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

20. The method according to claim 7, wherein the step of monitoring a first temperature, T.sub.1, is performed by means of a first temperature sensor arranged in the refrigerant path at an inlet opening of the evaporator, and/or the step of monitoring a second temperature, T.sub.2, is performed by means of a second temperature sensor arranged in the refrigerant path at an outlet opening of the evaporator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described in further details with reference to the accompanying drawings in which

(2) FIG. 1 is a diagrammatic view of a part of a vapour compression system used for performing the method according to an embodiment of the invention,

(3) FIG. 2 is a diagrammatic view of a part of a vapour compression system used for performing the method according to an alternative embodiment of the invention,

(4) FIG. 3 is a graph illustrating opening degree, inlet temperature and outlet temperature during start-up of a vapour compression system according to a first control strategy,

(5) FIG. 4 is a graph illustrating opening degree, inlet temperature and outlet temperature during start-up of a vapour compression system according to a second control strategy, and

(6) FIG. 5 is a flow diagram illustrating a method according to an embodiment of the invention.

DETAILED DESCRIPTION

(7) FIG. 1 is a diagrammatic view of a part of a vapour compression system 1. The vapour compression system 1 comprises a compressor 2, a condenser (not shown), an expansion device 3, in the form of an electronic expansion valve (EEV), and an evaporator 4, arranged along a refrigerant path 5. A first temperature sensor 6 is arranged in the refrigerant path 5 at an inlet opening of the evaporator 4, and a second temperature sensor 7 is arranged in the refrigerant path 5 at an outlet opening of the evaporator 4. Thus, the first temperature sensor 6 measures the temperature, T.sub.1, of refrigerant entering the evaporator 4, and the second temperature sensor 7 measures the temperature, T.sub.2, of refrigerant leaving the evaporator 4.

(8) The temperature signals, T.sub.1 and T.sub.2, are communicated to a control device 8 with the purpose of controlling the opening degree of the expansion device 3 in such a manner that an optimal superheat value is obtained. Accordingly, the control device 8 is adapted to generate and supply a control signal to the expansion device 3.

(9) Furthermore, the control device 8 receives an ON/OFF signal from the compressor 2 indicating whether the compressor is operating or not. This information is also taken into account when the control signal to the expansion device 3 is generated.

(10) During start-up of the vapour compression system 1, e.g. when the compressor 2 is started, the vapour compression system 1 may be operated according to an embodiment of the invention. Thus, on the basis of the temperature measurements performed by the temperature sensors 6, 7, it can be established if the evaporator 4 is full or almost full, or if the evaporator 4 is not full, and the opening degree of the expansion device 3 can then be controlled in accordance with the filling degree of the evaporator 4, as described above. This will be described in further detail below.

(11) FIG. 2 is a schematic view of a part of a vapour compression system 1, which is similar to the vapour compression system 1 of FIG. 1. In the vapour compression system 1 of FIG. 2, the evaporator 4 is of a kind comprising three evaporator coils. Accordingly, a distributor 9 is arranged in the refrigerant path 5 between the expansion device 3 and the evaporator 4. The distributor 9 splits the refrigerant flow from the expansion device 3 into three paths, each entering an evaporator coil of the evaporator 4. Similarly, a collector 10 collects the refrigerant leaving the evaporator 4 via the three evaporator coils into a single refrigerant flow.

(12) The first temperature sensor 6 is arranged in one of the three flow paths, between the distributor 9 and the evaporator 4. Thus, the first temperature sensor 6 measures the temperature of the refrigerant entering one of the evaporator coils. The second temperature sensor 7 is arranged in the collected refrigerant flow leaving the collector 10. Thus, the second temperature sensor 7 measures the temperature of the collected refrigerant from all three evaporator coils, and thereby the temperature of the refrigerant which is actually entering the suction line rather than the temperature of refrigerant leaving one of the evaporator coils.

(13) The temperatures measured by means of the temperature sensors 6, 7 shown in FIG. 2 can also be used as a basis for determining if the evaporator is full or almost full, or if the evaporator is not full.

(14) FIG. 3 is a graph illustrating opening degree 11 of an expansion device of a vapour compression system, the temperature 12 of refrigerant entering an evaporator of the vapour compression system, and the temperature 13 of refrigerant leaving the evaporator, as a function of time. The vapour compression system may be of the kind shown in FIG. 1 or of the kind shown in FIG. 2. In this case the temperature 12 of refrigerant entering the evaporator is measured by means of the first temperature sensor 6, and the temperature 13 of refrigerant leaving the evaporator is measured by means of the second temperature sensor 7.

(15) The graph of FIG. 3 illustrates a method of controlling the opening degree of the expansion device during start-up of the vapour compression system in the case that the evaporator is full or almost full when operation of the vapour compression system is started.

(16) At time 14 the operation of the vapour compression system is started, and the opening degree 11 of the expansion valve is increased to an intermediate level. The temperature 12 of refrigerant entering the evaporator and the temperature 13 of refrigerant leaving the evaporator are then monitored. More particularly, the rate of change of each of the monitored temperatures 12, 13 is derived, and the rates of change are compared to each other.

(17) In the situation illustrated in FIG. 3, the rate of change of the temperature 12 of refrigerant entering the evaporator is substantially identical to the rate of change of the temperature 13 of refrigerant leaving the evaporator. In other words, the temperature 12 of refrigerant entering the evaporator and the temperature 13 of refrigerant leaving the evaporator decrease in substantially the same manner immediately after operation of the vapour compression system has been started. This is an indication that the evaporator is full or almost full, since in this case the superheat of the refrigerant leaving the evaporator is very small. Thus, based on the monitoring of the refrigerant temperatures 12, 13 and on the derived rates of change of the temperatures 12, 13, it can be established that the evaporator is full or almost full.

(18) Since the evaporator is full or almost full, there is a risk that liquid refrigerant leaves the evaporator and enters the suction line. As described above, this is undesirable, since liquid refrigerant may cause damage if it is allowed to reach the compressor. Therefore, in order to avoid that liquid refrigerant leaves the evaporator, the refrigerant supply to the evaporator is decreased by gradually decreasing the opening degree 11 of the expansion device.

(19) While the opening degree 11 of the expansion device is gradually decreased, the difference between the temperature 12 of refrigerant entering the evaporator and the temperature of refrigerant leaving the evaporator is monitored. It can be seen in FIG. 3 that, at a certain point in time, the temperature 13 of refrigerant leaving the evaporator starts to increase, while the temperature 12 of refrigerant entering the evaporator continues to decrease. Thereby the temperature difference between the measured temperatures 12, 13 increases. This is an indication that the filling degree of the evaporator has decreased to a level where the superheat of the refrigerant leaving the evaporator is no longer minimal, and the vapour compression system is therefore not operated in an optimal manner. Therefore it is no longer desirable to decrease the supply of refrigerant to the evaporator, and the decreasing of the opening degree 11 of the expansion device is therefore discontinued when this behaviour is detected. In addition, the opening degree 11 of the expansion device may subsequently be gradually increased, until it is detected that the evaporator is once again full or almost full. However, this is not illustrated in FIG. 3.

(20) FIG. 4 is also a graph illustrating opening degree 11 of an expansion device of a vapour compression system, the temperature 12 of refrigerant entering an evaporator of the vapour compression system, and the temperature 13 of refrigerant leaving the evaporator, as a function of time. The vapour compression system may be of the kind shown in FIG. 1 or of the kind shown in FIG. 2. In this case the temperature 12 of refrigerant entering the evaporator is measured by means of the first temperature sensor 6, and the temperature 13 of refrigerant leaving the evaporator is measured by means of the second temperature sensor 7.

(21) The graph of FIG. 4 illustrates a method of controlling the opening degree of the expansion device during start-up of the vapour compression system in the case that the evaporator is not full when operation of the vapour compression system is started.

(22) At time 14 the operation of the vapour compression system is started, and the opening degree 11 of the expansion valve is increased to an intermediate level. The temperature 12 of refrigerant entering the evaporator and the temperature 13 of refrigerant leaving the evaporator are then monitored. More particularly, the rate of change of each of the monitored temperatures 12, 13 is derived, and the rates of change are compared to each other. This is exactly the same process which is described above with reference to FIG. 3. Thus, each time the vapour compression system is started, the intermediate level of the opening degree 11 of the expansion device is selected, and the rates of change of the refrigerant temperatures 12, 13 are monitored and compared in order to determine if the evaporator is full or almost full, or if the evaporator is not full.

(23) In the situation illustrated in FIG. 4, the temperature 12 of refrigerant entering the evaporator decreases faster than the temperature 13 of refrigerant leaving the evaporator. This indicates that gaseous and heated refrigerant is leaving the evaporator, and thereby that the evaporator is not full. It is desirable to reach a maximum filling degree of the evaporator as quickly as possible, because the most efficient operation of the vapour compression system is obtained at maximum filling degree. Therefore, when this situation is detected, the supply of refrigerant to the evaporator is increased by gradually increasing the opening degree 11 of the expansion device. Furthermore, this can safely be done, since it has already been established that the evaporator is not full, and there is therefore no risk that an increased refrigerant supply to the evaporator will result in liquid refrigerant passing through the evaporator.

(24) While the opening degree 11 of the expansion device is gradually increased, the rate of change of the temperature 13 of refrigerant leaving the evaporator is monitored. It can be seen in FIG. 4 that at a certain point in time, the temperature 13 of refrigerant leaving the evaporator decreases drastically. This is an indication that the evaporator is full or almost full, since in this case the temperature 13 of refrigerant leaving the evaporator will quickly approach the liquid temperature, since the gaseous refrigerant leaving the evaporator is no longer heated in the evaporator. When the evaporator is full or almost full, there is a risk that liquid refrigerant may pass through the evaporator, and it is therefore no longer desirable to increase the supply of refrigerant to the evaporator, and the gradual increase in opening degree 11 of the expansion device is therefore discontinued. Furthermore, the opening degree 11 of the expansion device is decreased to the initial, intermediate level at this point. Subsequently the opening degree 11 of the expansion device is controlled in a usual manner in order to obtain an optimal superheat value.

(25) FIGS. 3 and 4 illustrate that each time the vapour compression system is started, the same initial steps are performed, and an intermediate opening degree 11 of the expansion device is selected. Then it is determined, based on the monitored rates of change of the temperatures 12, 13, if the evaporator is full or almost full, or if the evaporator is not full. If it is determined that the evaporator is full or almost full, the careful approach illustrated in FIG. 3 is selected in order to avoid that liquid refrigerant passes through the evaporator. If it is determined that the evaporator is not full, the more aggressive approach illustrated in FIG. 4 is selected in order to ensure that the maximum filling degree is reached as quickly as possible.

(26) Thus, regardless of whether or not the evaporator is initially full, it is ensured that a maximum filling degree is quickly reached, while it is ensured that liquid refrigerant is not allowed to pass through the evaporator.

(27) FIG. 5 is a flow chart illustrating a method according to an embodiment of the invention. The process is started at step 15, where the vapour compression system is started, and a low opening degree of the expansion device is selected. The rate of change of the temperature of refrigerant entering the evaporator and the rate of change of the temperature of refrigerant leaving the evaporator are then monitored. If nothing happens, the process times out, and an alarm is initiated at step 16, informing an operator that the opening degree of the expansion device is low.

(28) If it is determined that the rate of change of the temperature of refrigerant entering the evaporator, or the rate of change of the temperature of refrigerant leaving the evaporator is under a given threshold value, the opening degree of the expansion device is increased to an intermediate level, at step 17.

(29) If it is then determined that the rate of change of the temperature of refrigerant leaving the evaporator is over the threshold after some time, it is an indication that the superheat value is still high. Therefore the opening degree of the expansion device is, in this case, increased gradually, at step 18. If nothing happens, the process times out, and an alarm is initiated at step 16.

(30) If, after step 18, it is determined that the rate of change of the temperature of refrigerant leaving the evaporator is under the threshold value, and that the temperature or refrigerant leaving the evaporator has decreased significantly since start-up, it is an indication that the superheat value is decreasing. Therefore the gradual increase in opening degree of the expansion device is discontinued, and the opening degree is decreased to the initial, intermediate value, at step 19.

(31) Then, at step 20, the opening degree of the expansion device is adjusted in order to obtain stabilisation of the superheat in the range of 5-15 K.

(32) If, at step 17, it is determined that the rate of change of the temperature of refrigerant leaving the evaporator is under the threshold value, and that the temperature of refrigerant leaving the evaporator has decreased significantly since start-up, it is an indication that the superheat value is decreasing. Then the process is proceeded to step 20, described above.

(33) Once the superheat value is within the desired band, the start-up procedure is ended, and normal control of the opening degree of the expansion device is commenced, at step 21.

(34) The embodiments of the invention described above are provided by way of example only. The skilled person will be aware of many modifications, changes and substitutions that could be made without departing from the scope of the present invention. The claims of the present invention are intended to cover all such modifications, changes and substitutions as fall within the spirit and scope of the invention.