Compressor data module

Abstract

A compressor includes a shell, a compression mechanism, a motor, a data module, and a compressor controller. The data module includes a processor and a memory. The compressor controller includes a processor and a memory. The data module receives sensed data, stores sensed data in the memory, and communicates sensed data to the compressor controller. The compressor controller controls a capacity of the compressor based on the sensed data and is operable to communicate with a system controller of a refrigeration system.

1 . A compressor comprising a shell, a compression mechanism, a motor, a data module, and a compressor controller, said data module including a processor and a memory, said compressor controller including a processor and a memory, said data module receiving sensed data, storing sensed data in said memory, and communicating sensed data to said compressor controller, said compressor controller controlling a capacity of the compressor based on said sensed data and operable to communicate with a system controller of a refrigeration system. 
   
   
       2 . The compressor of  claim 1 , wherein said data module processor determines non-measured operating parameters of at least one of the compressor and said refrigeration system based on said sensed data. 
   
   
       3 . The compressor of  claim 2 , wherein said non-measured operating parameters include subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature. 
   
   
       4 . The compressor of  claim 2 , wherein said data module communicates said non-measured operating parameters to at least one of said system controller and said compressor controller. 
   
   
       5 . The compressor of  claim 2 , wherein said data module diagnoses at least one of the compressor and said refrigeration system based on at least one of said sensed data and said non-measured operating parameters. 
   
   
       6 . The compressor of  claim 5 , wherein said data module communicates said diagnosis to at least one of said system controller and said compressor controller. 
   
   
       7 . The compressor of  claim 1 , wherein said data module diagnoses at least one of the compressor and said refrigeration system based on said sensed data. 
   
   
       8 . The compressor of  claim 7 , wherein said data module communicates said diagnosis to at least one of said system controller and said compressor controller. 
   
   
       9 . The compressor of  claim 1 , wherein said compressor controller diagnoses at least one of the compressor and said refrigeration system based on said sensed data from said data module. 
   
   
       10 . The compressor of  claim 9 , wherein said compressor controller communicates said diagnosis to said system controller. 
   
   
       11 . The compressor of  claim 1 , wherein said data module and said compressor controller are attached to the compressor. 
   
   
       12 . For a refrigeration system including a system controller in communication with a compressor controller associated with a compressor, a data module comprising a housing, a processor and a memory, said housing mountable on the compressor, said processor receiving sensed data, storing sensed data in said memory, and operable to communicate sensed data to the compressor controller. 
   
   
       13 . The data module of  claim 12 , wherein said data module processor determines non-measured operating parameters of at least one of said compressor and said refrigeration system based on said sensed data. 
   
   
       14 . The compressor of  claim 14 , wherein said non-measured operating parameters include subcooling, condenser temperature, condenser temperature difference, suction superheat, discharge superheat, and evaporator temperature. 
   
   
       15 . The data module of  claim 13 , wherein said data module processor communicates said non-measured operating parameters to at least one of said system controller and said compressor controller. 
   
   
       16 . The data module of  claim 13 , wherein said data module processor diagnoses at least one of said compressor and said refrigeration system based on at least one of said sensed data and said non-measured operating parameters. 
   
   
       17 . The data module of  claim 13 , wherein said data module processor communicates said diagnosis to at least one of said system controller and said compressor controller. 
   
   
       18 . The data module of  claim 12 , wherein said data module processor diagnoses at least one of said compressor and said refrigeration system based on said sensed data. 
   
   
       19 . The data module of  claim 18 , wherein said data module processor communicates said diagnosis to at least one of said system controller and said compressor controller. 
   
   
       20 . The data module of  claim 12 , wherein said compressor controller diagnoses at least one of said compressor and said refrigeration system based on said sensed data from said data module processor. 
   
   
       21 . The data module of  claim 20 , wherein said compressor controller communicates said diagnosis to said system controller. 
   
   
       22 . A compressor control system comprising:
 a compressor;   a compressor controller operable to diagnose and/or control said compressor; and   a data module associated with said compressor and in communication with said compressor controller, said data module receiving sensor data indicative of compressor performance, determining non-measured system operating parameters, and diagnosing said compressor based on at least one of said sensor data and said non-measured system operating parameters, said data module communicating said sensor data, said non-measured system operating parameters, and said diagnosis to said compressor controller.   
   
   
       23 . The compressor of  claim 22 , wherein said compressor controller determines said non-measured system operating parameters based on said received sensor data and diagnoses said compressor based on at least one of said received sensor data and said determined non-measured system operating parameters, said compressor controller comparing said determined non-measured system operating parameters to said non-measured system operating parameters received from said data module and comparing said determined diagnosis to said diagnosis received from said data module. 
   
   
       24 . A method comprising:
 communicating sensor data to a data module;   processing said sensor data at said data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system;   processing at least one of said sensor data and said determined non-measured operating parameters at said data module to diagnose said at least one compressor and refrigeration system;   communicating said sensor data, said non-measured operating parameters, and said diagnosis to a system controller;   determining said non-measured operating parameters at said system controller based on said received sensor data;   determining said diagnosis at said system controller based on said received sensor data and said determined non-measured operating parameters;   comparing said received non-measured operating parameters to said determined non-measured operating parameters at said system controller; and   comparing said received diagnosis to said determined diagnosis at said system controller.   
   
   
       25 . A method comprising:
 communicating sensor data to a data module;   processing said sensor data at said data module to determine non-measured operating parameters of at least one of a compressor and a refrigeration system;   processing at least one of said sensor data and said non-measured operating parameters at said data module to diagnose said at least one compressor and refrigeration system;   storing at least one of said sensor data, said non-measured operating parameters, and said diagnosis in a memory of said data module;   communicating at least one of said sensor data, said non-measured operating parameters, and said diagnosis to a first system controller;   replacing said first system controller with a second system controller; and   communicating at least one of said stored sensor data, said stored non-measured operating parameters, and said stored diagnosis to said second controller.