Compressor capacity modulation

Abstract

A pulsed modulated capacity modulation system for refrigeration, air conditioning or other types of compressors is disclosed in which suitable valving is provided which operates to cyclically block flow of suction gas to a compressor. A control system is provided which is adapted to control both the frequency of cycling as well as the relative duration of the on and off time periods of each cycle in accordance with sensed system operating conditions so as to maximize the efficiency of the system. Preferably the cycle time will be substantially less than the time constant of the load and will enable substantially continuously variable capacity modulation from substantially zero capacity to the full capacity of the compressor. Additional controls may be incorporated to modify one or more of the motor operating parameters to improve the efficiency of the motor during periods of reduced load.

1. A capacity modulated compressor comprising:
 a compression mechanism disposed between a discharge passage and a suction chamber, said compression mechanism having a compression chamber therein, a suction inlet for supplying suction gas to the  said compression chamber and a movable member operative to vary the volume of said compression chamber;  
 a power source operatively connected to effect movement of said movable member to thereby compress gas drawn into said compression chamber through said suction inlet;  
 a valve disposed in said suction chamber and provided in the suction gas flow path to said compression mechanism, said valve being operable between open and closed positions to cyclically allow and prevent flow of suction gas into said compression chamber; and  
 control apparatus for actuating said valve between said open and closed positions, said control apparatus being operative to cycle said valve for a time duration such that its cycle time is substantially smaller than the time constant of the load on said compressor.  
 
     
     
       2. A capacity modulated compressor as set forth in  claim 1  wherein said valve is positioned in close proximity to said compression chamber. 
     
     
       3. A capacity modulated compressor as set forth in  claim 1  wherein said valve is a bidirectional valve. 
     
     
       4. A capacity modulated compressor as set forth in  claim 1  wherein at least one of said cycle time and the  said time duration said valve is in said closed position is varied in response to sensed operating conditions. 
     
     
       5. A capacity modulated compressor as set forth in  claim 4  wherein said power source continues to effect movement of said movable member as said valve is cycled between said open and closed positions. 
     
     
       6. A capacity modulated compressor as set forth in  claim 4  wherein said cycle time and said time duration are varied in response to said sensed operating condition. 
     
     
       7. A capacity modulated compressor as set forth in  claim 1  wherein said valve is actuated by pressurized fluid. 
     
     
       8. A capacity modulated compressor as set forth in  claim 7  further comprising a control valve operative to control the flow of pressurized fluid to said valve. 
     
     
       9. A capacity modulated compressor as set forth in  claim 8  wherein said control valve is a solenoid actuated valve. 
     
     
       10. A capacity modulated compressor as set forth in  claim 7  wherein said pressurized fluid is supplied from said compression mechanism. 
     
     
       11. A capacity modulated compressor as set forth in  claim 1  wherein said power source comprises an electric motor. 
     
     
       12. A capacity modulated compressor as set forth in  claim 11  wherein said control module operates to vary an operating parameter of said electric motor when said valve is in said closed position so as to thereby improve the operating efficiency of said motor. 
     
     
       13. A capacity modulated compressor as set forth in  claim 12  wherein said operating parameter of said motor is varied a predetermined time period after said valve is moved to said closed position. 
     
     
       14. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism is a reciprocating piston compressor. 
     
     
       15. A capacity modulated compressor as set forth in  claim 14  wherein said reciprocating piston compressor includes a plurality of pistons and cylinders, said valve being operative to prevent flow of suction gas to all of said cylinders. 
     
     
       16. A capacity modulated compressor as set forth in  claim 15  wherein said valve operates to prevent flow of suction gas to all of said cylinders simultaneously. 
     
     
       17. A capacity modulated compressor comprising:
 a hermetic shell including a suction chamber;  
 a compression mechanism disposed within said shell, said compression mechanism including a compression chamber defined in part by a moveable  movable member, said moveable  movable member operating to vary the volume thereof;  
 a drive shaft rotatably supported within said shell and drivingly coupled to said movable member;  
 a motor disposed in said suction chamber and operable to rotatably drive said drive shaft;  
 a suction inlet passage for supplying suction gas to said compression chamber from a source remote from said shell;  
 a valve assembly including a valve member within said suction inlet passage, said valve member being actuable between an open position to allow flow of suction gas through said inlet passage and a closed position to substantially prevent flow of suction gas through said suction inlet passage;  
 a controller for cyclically actuating said valve member to an open position for first predetermined time periods and to a closed position for second predetermined time periods, the ratio of said first predetermined time period to the sum of said first and second predetermined time periods being less than a given load time constant and determining the percentage modulation of the capacity of said compressor.  
 
     
     
       18. A capacity modulated compressor as set forth in  claim 17  wherein said valve assembly is a bidirectional valve and is actuable to said closed position by pressurized fluid. 
     
     
       19. A capacity modulated compressor as set forth in  claim 18  further comprising a solenoid valve actuable by said controller to control flow of said pressurized fluid to said valve assembly. 
     
     
       20. A capacity modulated compressor as set forth in  claim 19  wherein said pressurized fluid is discharge gas from said compressor. 
     
     
       21. A capacity modulated compressor as set forth in  claim 17  wherein said valve is positioned in close proximity to said compression chamber. 
     
     
       22. A capacity modulated compressor as set forth in  claim 17  wherein said compressor is a refrigeration compressor. 
     
     
       23. A capacity modulated compressor as set forth in  claim 17  wherein said compressor is an air compressor. 
     
     
       24. A capacity modulated compressor as set forth in  claim 17  wherein said compressor is a rotary compressor. 
     
     
       25. A capacity modulated compressor as set forth in  claim 17  wherein said compressor is a scroll compressor. 
     
     
       26. A capacity modulated compressor as set forth in  claim 17  wherein said sum of said first and second time periods is less than one half of said load time constant. 
     
     
       27. A capacity modulated compressor as set forth in  claim 17  further comprising a motor for rotatably driving said drive shaft,  wherein said valve being  member is actuable between said open and closed positions while said motor continues to rotatably drive said drive shaft. 
     
     
       28. A capacity modulated compressor as set forth in  claim 27  wherein said controller operates to vary an operating parameter of said motor between periods in which said valve member is in said closed position and in said open position to thereby improve the operating efficiency of said motor. 
     
     
       29. A method of modulating the capacity of a compressor forming a part of a cooling system to accommodate varying cooling load conditions comprising:
 sensing an operating parameter of said cooling system, said parameter being indicative of the system load;  
 determining a cycle frequency of  and a maximum time duration which will minimize variation in the suction pressure of refrigerant being supplied to said compressor;  
 determining a first time period during which suction gas will be supplied to said compressor and determining a second time period during which suction gas will be prevented from flowing to said compressor, said first and second time periods being equal to said cycle frequency; and  
 pulsing a valve between open and closed positions for said first and second time periods respectively to thereby modulate the capacity of said compressor in response to said system operating parameter; and  
 varying a motor operating parameter when said valve is in said closed position.  
 
     
     
       30. A capacity modulated compressor as set forth in  claim 1  wherein said valve is a solenoid valve. 
     
     
       31. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism includes a piston reciprocably disposed in a cylinder. 
     
     
       32. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism includes a compression rotor and vane disposed in a cylinder. 
     
     
       33. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism includes interleaved scroll members defining moving fluid pockets. 
     
     
       34. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism compresses air. 
     
     
       35. A capacity modulated compressor as set forth in  claim 17  wherein said valve is a solenoid valve. 
     
     
       36. A capacity modulated compressor as set forth in  claim 17  wherein said compression mechanism includes a piston reciprocably disposed in a cylinder. 
     
     
       37. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism includes a compression rotor and vane disposed in a cylinder. 
     
     
       38. A capacity modulated compressor as set forth in  claim 1  wherein said compression mechanism includes interleaved scroll members defining moving fluid pockets. 
     
     
       39. A capacity modulated compressor as set forth in  claim 17  wherein said valve is disposed in the suction gas flow path between said power source and said compression mechanism. 
     
     
       40. A capacity modulated compressor as set forth in  claim 1  wherein said power source is disposed in said suction chamber. 
     
     
       41. A capacity modulated compressor as set forth in  claim 40  wherein said cycle time and said time duration are varied in response to a sensed operating condition. 
     
     
       42. A capacity modulated compressor as set forth in  claim 40  wherein at least one of said cycle time and the time duration said valve is in said closed position is varied in response to a sensed operating condition. 
     
     
       43. A capacity modulated compressor as set forth in  claim 40  wherein said valve is actuated by a pressurized fluid. 
     
     
       44. A capacity modulated compressor as set forth in  claim 43  further comprising a control valve operative to control a flow of said pressurized fluid to said valve. 
     
     
       45. A capacity modulated compressor as set forth in  claim 44  wherein said control valve is a solenoid actuated valve. 
     
     
       46. A capacity modulated compressor as set forth in  claim 43  wherein said pressurized fluid is supplied from said compression mechanism. 
     
     
       47. A capacity modulated compressor as set forth in  claim 40  wherein said compression mechanism includes a piston reciprocably disposed in a cylinder. 
     
     
       48. A capacity modulated compressor as set forth in  claim 40  wherein said compression mechanism includes a compression rotor and vane disposed in a cylinder. 
     
     
       49. A capacity modulated compressor as set forth in  claim 40  wherein said compression mechanism includes interleaved scroll members defining moving fluid pockets. 
     
     
       50. A capacity modulated compressor as set forth in  claim 40  wherein said control apparatus operates to vary an operating parameter of said power source when said valve is in said closed position. 
     
     
       51. A capacity modulated compressor as set forth in  claim 40  wherein said valve is a solenoid valve. 
     
     
       52. A capacity modulated compressor as set forth in  claim 1  wherein said valve is disposed in said suction gas flow path between said power source and said compression mechanism. 
     
     
       53. A capacity modulated compressor as set forth in  claim 52  wherein said cycle time and said time duration are varied in response to a sensed operating condition. 
     
     
       54. A capacity modulated compressor as set forth in  claim 52  wherein at least one of said cycle time and the time duration said valve is in said closed position is varied in response to a sensed operating condition. 
     
     
       55. A capacity modulated compressor as set forth in  claim 52  wherein said valve is actuated by a pressurized fluid. 
     
     
       56. A capacity modulated compressor as set forth in  claim 55  further comprising a control valve operative to control a flow of said pressurized fluid to said valve. 
     
     
       57. A capacity modulated compressor as set forth in  claim 56  wherein said control valve is a solenoid actuated valve. 
     
     
       58. A capacity modulated compressor as set forth in  claim 55  wherein said pressurized fluid is supplied from said compression mechanism. 
     
     
       59. A capacity modulated compressor as set forth in  claim 52  wherein said compression mechanism includes a piston reciprocably disposed in a cylinder. 
     
     
       60. A capacity modulated compressor as set forth in  claim 52  wherein said compression mechanism includes a compression rotor and vane disposed in a cylinder. 
     
     
       61. A capacity modulated compressor as set forth in  claim 52  wherein said compression mechanism includes interleaved scroll members defining moving fluid pockets. 
     
     
       62. A capacity modulated compressor as set forth in  claim 52  wherein said control apparatus operates to vary an operating parameter of said power source when said valve is in said closed position. 
     
     
       63. A capacity modulated compressor as set forth in  claim 52  wherein said valve is a solenoid valve. 
     
     
       64. A capacity modulated compressor as set forth in  claim 1  further comprising a hermetic shell defining said suction chamber. 
     
     
       65. A capacity modulated compressor as set forth in  claim 64  wherein said cycle time and said time duration are varied in response to a sensed operating condition. 
     
     
       66. A capacity modulated compressor as set forth in  claim 64  wherein at least one of said cycle time and the time duration said valve is in said closed position is varied in response to a sensed operating condition. 
     
     
       67. A capacity modulated compressor as set forth in  claim 64  wherein said valve is actuated by a pressurized fluid. 
     
     
       68. A capacity modulated compressor as set forth in  claim 67  further comprising a control valve operative to control a flow of said pressurized fluid to said valve. 
     
     
       69. A capacity modulated compressor as set forth in  claim 68  wherein said control valve is a solenoid actuated valve. 
     
     
       70. A capacity modulated compressor as set forth in  claim 67  wherein said pressurized fluid is supplied from said compression mechanism. 
     
     
       71. A capacity modulated compressor as set forth in  claim 64  wherein said compression mechanism includes a piston reciprocably disposed in a cylinder. 
     
     
       72. A capacity modulated compressor as set forth in  claim 64  wherein said compression mechanism includes a compression rotor and vane disposed in a cylinder. 
     
     
       73. A capacity modulated compressor as set forth in  claim 64  wherein said compression mechanism includes interleaved scroll members defining moving fluid pockets. 
     
     
       74. A capacity modulated compressor as set forth in  claim 64  wherein said control apparatus operates to vary an operating parameter of said power source when said valve is in said closed position. 
     
     
       75. A capacity modulated compressor as set forth in  claim 64  wherein said valve is a solenoid valve. 
     
     
       76. A capacity modulated compressor comprising:
   a compression mechanism disposed between a discharge passage and a suction chamber, said compression mechanism having a compression chamber therein, a suction inlet for supplying suction gas to said compression chamber and a movable member operative to vary the volume of said compression chamber;        a power source disposed in said suction chamber and operatively connected to effect movement of said movable member to thereby compress gas drawn into said compression chamber through said suction inlet;        a valve assembly mounted to said compression mechanism and including a valve member provided in a suction gas flow path to said compression mechanism, said valve being operable between open and closed positions to cyclically allow and prevent flow of suction gas into said compression chamber; and        control apparatus for actuating said valve between said open and closed positions, said control apparatus being operative to cycle said valve for a time duration such that its cycle time is substantially smaller than the time constant of the compressor load.     
     
     
       77. A capacity modulated compressor as set forth in  claim 76  wherein at least one of said cycle time and said time duration said valve is in said closed position is varied in response to sensed operating conditions. 
     
     
       78. A capacity modulated compressor as set forth in  claim 76  wherein said power source continues to effect movement of said movable member as said valve is cycled between said open and closed positions. 
     
     
       79. A capacity modulated compressor as set forth in  claim 76  wherein said cycle time and said time duration are varied in response to a sensed operating condition. 
     
     
       80. A capacity modulated compressor as set forth in  claim 76  wherein said valve is actuated by a pressurized fluid. 
     
     
       81. A capacity modulated compressor as set forth in  claim 80  further comprising a control valve operative to control a flow of said pressurized fluid to said valve. 
     
     
       82. A capacity modulated compressor as set forth in  claim 81  wherein said control valve is a solenoid actuated valve. 
     
     
       83. A capacity modulated compressor as set forth in  claim 80  wherein said pressurized fluid is supplied from said compression mechanism. 
     
     
       84. A capacity modulated compressor as set forth in  claim 76  wherein said power source includes an electric motor. 
     
     
       85. A capacity modulated compressor as set forth in  claim 84  wherein said control module operates to vary an operating parameter of said electric motor when said valve is in said closed position. 
     
     
       86. A capacity modulated compressor as set forth in  claim 85  wherein said operating parameter of said motor is varied a predetermined time period after said valve is moved to said closed position. 
     
     
       87. A capacity modulated compressor as set forth in  claim 76  wherein said valve is a solenoid valve. 
     
     
       88. A capacity modulated compressor as set forth in  claim 76  wherein said compression mechanism includes a piston reciprocably disposed in a cylinder. 
     
     
       89. A capacity modulated compressor as set forth in  claim 76  wherein said compression mechanism includes a compression rotor and vane disposed in a cylinder. 
     
     
       90. A capacity modulated compressor as set forth in  claim 76  wherein said compression mechanism includes interleaved scroll members defining moving fluid pockets. 
     
     
       91. A capacity modulated compressor as set forth in  claim 76  wherein said valve is disposed in said suction gas flow path between said power source and said compression mechanism. 
     
     
       92. A capacity modulated compressor as set forth in  claim 76  further comprising a hermetic shell defining said suction chamber. 
     
     
       93. A capacity modulated compressor as set forth in  claim 12  wherein varying an operating parameter of said electric motor includes adjusting voltage or varying a running capacitance of a winding of said electric motor. 
     
     
       94. A capacity modulated compressor as set forth in  claim 28  wherein varying an operating parameter of said electric motor includes adjusting voltage or varying a running capacitance of a winding of said electric motor. 
     
     
       95. A capacity modulated compressor as set forth in  claim 29  wherein varying an operating parameter of said electric motor includes adjusting voltage or varying a running capacitance of a winding of said electric motor. 
     
     
       96. A capacity modulated compressor as set forth in  claim 85  wherein varying an operating parameter of said electric motor includes adjusting voltage or varying a running capacitance of a winding of said electric motor.