CN100513791C - 采用脉冲宽度调节工作循环的涡卷压缩机的冷冻系统的自适应控制 - Google Patents

采用脉冲宽度调节工作循环的涡卷压缩机的冷冻系统的自适应控制 Download PDF

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CN100513791C
CN100513791C CNB2005100648602A CN200510064860A CN100513791C CN 100513791 C CN100513791 C CN 100513791C CN B2005100648602 A CNB2005100648602 A CN B2005100648602A CN 200510064860 A CN200510064860 A CN 200510064860A CN 100513791 C CN100513791 C CN 100513791C
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control
compressor
temperature
control system
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CN1664373A (zh
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亨·M·潘
阿布诺·辛格
让-鲁克·M·卡亚
马克·拜司
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Copeland LP
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D23/00—Control of temperature
    • G05D23/19—Control of temperature characterised by the use of electric means
    • G05D23/1906—Control of temperature characterised by the use of electric means using an analogue comparing device
    • G05D23/1909—Control of temperature characterised by the use of electric means using an analogue comparing device whose output amplitude can only take two discrete values
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B49/00—Arrangement or mounting of control or safety devices
    • F25B49/02—Arrangement or mounting of control or safety devices for compression type machines, plants or systems
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47F—SPECIAL FURNITURE, FITTINGS, OR ACCESSORIES FOR SHOPS, STOREHOUSES, BARS, RESTAURANTS OR THE LIKE; PAYING COUNTERS
    • A47F3/00—Show cases or show cabinets
    • A47F3/04—Show cases or show cabinets air-conditioned, refrigerated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
    • F04C18/02—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents
    • F04C18/0207—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form
    • F04C18/0215—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form where only one member is moving
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C27/00—Sealing arrangements in rotary-piston pumps specially adapted for elastic fluids
    • F04C27/005—Axial sealings for working fluid
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/02—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids specially adapted for several pumps connected in series or in parallel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/06—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids specially adapted for stopping, starting, idling or no-load operation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/08—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by varying the rotational speed
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/18—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by varying the volume of the working chamber
    • F04C28/22—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by varying the volume of the working chamber by changing the eccentricity between cooperating members
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/24—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by using valves controlling pressure or flow rate, e.g. discharge valves or unloading valves
    • F04C28/26—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by using valves controlling pressure or flow rate, e.g. discharge valves or unloading valves using bypass channels
    • F04C28/265—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by using valves controlling pressure or flow rate, e.g. discharge valves or unloading valves using bypass channels being obtained by displacing a lateral sealing face
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/28—Safety arrangements; Monitoring
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B1/00—Compression machines, plants or systems with non-reversible cycle
    • F25B1/04—Compression machines, plants or systems with non-reversible cycle with compressor of rotary type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B41/00—Fluid-circulation arrangements
    • F25B41/20—Disposition of valves, e.g. of on-off valves or flow control valves
    • F25B41/22—Disposition of valves, e.g. of on-off valves or flow control valves between evaporator and compressor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B49/00—Arrangement or mounting of control or safety devices
    • F25B49/005—Arrangement or mounting of control or safety devices of safety devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B49/00—Arrangement or mounting of control or safety devices
    • F25B49/02—Arrangement or mounting of control or safety devices for compression type machines, plants or systems
    • F25B49/022—Compressor control arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B5/00—Compression machines, plants or systems, with several evaporator circuits, e.g. for varying refrigerating capacity
    • F25B5/02—Compression machines, plants or systems, with several evaporator circuits, e.g. for varying refrigerating capacity arranged in parallel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2270/00—Control; Monitoring or safety arrangements
    • F04C2270/01—Load
    • F04C2270/015—Controlled or regulated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2270/00—Control; Monitoring or safety arrangements
    • F04C2270/86—Detection
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C23/00—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids
    • F04C23/008—Hermetic pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B2400/00—General features or devices for refrigeration machines, plants or systems, combined heating and refrigeration systems or heat-pump systems, i.e. not limited to a particular subgroup of F25B
    • F25B2400/22—Refrigeration systems for supermarkets
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
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    • F25B2600/0261—Compressor control by controlling unloaders external to the compressor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
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    • F25B2700/19—Pressures
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
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    • F25B41/30—Expansion means; Dispositions thereof
    • F25B41/31—Expansion valves
    • F25B41/34—Expansion valves with the valve member being actuated by electric means, e.g. by piezoelectric actuators
    • F25B41/35—Expansion valves with the valve member being actuated by electric means, e.g. by piezoelectric actuators by rotary motors, e.g. by stepping motors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
    • Y02B30/70—Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

利用一台特殊的脉冲宽度调节的压缩机(30)耦联到冷凝器(32)和蒸发器(42)上来控制一个冷冻系统。系统可以是分布式的，其中冷凝器(32)和压缩机(30)可耦合在一起对付一组相邻的冷冻柜，而每一冷冻柜有其自己的蒸发器(42)。控制器(52)被耦联到负载传感器(58)上用来产生可变工作循环控制信号，而工作循环为冷却需求的函数。另外，可利用模糊逻辑技术来使该系统进行自适应调谐控制。

Description

采用脉冲宽度调节工作循环的涡卷压缩机的冷冻系统的自适应控制
相关申请的交叉参考
本申请是序号为08/486,118号、1995.06.07立案的、题为“可调节容量的涡卷机械”的申请的后续部分。
本发明的背景和综述
本发明一般地涉及冷冻系统、压缩机控制系统和致冷剂调节阀控制系统。更具体点说，涉及一个采用由负载传感器导出的可变工作循环信号控制的调节脉冲宽度的压缩机或蒸发器分档调节器的冷冻系统。最好有自适应的控制器产生可变工作循环信号。该压缩机具有两个被密封隔开的机械元件，而这两个机械元件可循环地相互相对运动来产生流体压力。该压缩机包括一个机构可根据控制信号有选择地断开密封，从而调节系统的容量。
冷冻系统可用作对冷冻柜和类似物的分配系统。较优的布置允许压缩机和冷凝器的子系统设置在冷冻柜内或安装在其上，从而可大大减少致冷剂导管的长度和所需的致冷剂。
传统上，超市冷冻柜用的冷冻系统采用由一排压缩机供给的空冷或水冷的冷凝器。这些压缩机被平行地连接(并联)，使它们在各阶段可分别被开通和关断以资按负载的需求来调节系统的冷却容量。通常冷凝器位在外面的屋顶上，或在与设有冷冻柜的购物区域邻近的机器间内。
在每一冷冻柜内有一由来自冷凝器的管线供给的蒸发器，膨胀的致冷剂通过该管线循环使柜冷却。传统上，有一闭环控制系统调节通过蒸发器流动的致冷剂以资维持所需的柜温。用于这个目的的比例积分微商(PID)闭环控制系统是广为人知的，由温度传感器及/或压力传感器提供所感知的状态作为输入。
在超市内通常的做法是用分开的系统来提供不同的单独的冷却温度范围：低温(用于冷冻食品、冰淇淋，正常为-25℉)；中温(用于肉类、奶制品，正常为+20℉)；高温(用于花卉制品，正常为+35到+40℉)。这些低、中、高温系统在其各自的温度范围内都是最优的。通常每一系统各采用自己的一排压缩机和自己的一套致冷剂导管与压缩机和冷凝器来往。
上述传统的配置在构造和维护时都很花钱。大部分费用与敷设长的致冷剂导管有关。不仅敷设长的导管就硬件和安装费用来说是费钱的，而且需要用来填充导管的致冷剂的数量也是一个有影响的因素。敷设的导管越长，需要的致冷剂越多。增加在费用上的还有环保因素。万一管配件泄漏，致冷剂便会逸入大气中。而长的导管一定会包括较多的管配件接头，它们是潜在地有可能泄漏的。一旦泄漏发生，导管越长，致冷剂的丧失也会越多。
当今人们非常关注有利于环保的冷冻系统。缩短导管长度看来是达到更有利于环保的系统的一条途径。但要达到这一点，新的冷凝器/压缩机的配置和新的控制系统都需设计。
为更有利于环保的系统重新设计冷凝器/压缩机的配置并不是一个简单的任务，因为系统的效率是不应牺牲的。一般地说，由压缩机供应的、传统的、装在屋顶上的冷凝器系统就规模经济来看是有利的并且是十分有效的。这些系统应作为基准，未来的更有利于环保的系统应以此来衡量。
为了评价重新设计一个有利环保而有效的系统为什么这样难，可先考虑下面这些热动力学的问题。典型的冷冻柜是在非常不可预见的环境下工作的。从设计立场来看，要被冷冻的热负载很少是恒定的。在超市的环境内温、湿度在白天的不同时间和在一年中的不同季节可有很大的变化。物品负载(放在冷冻柜内的物件)也能有不可预见的变化。取走物品的顾客和重新补充物品的店员很少是同步的。而在超市环境之外，户外的温、湿度也可在白天和黑夜之间及/或夏天和冬天之间有很大的变化。因此系统的容量必须按照最严厉的条件(其时冷凝器的环境为最热)来设计。这样系统在较不严厉的条件下如在冷夜或冬天就会有过剩的容量。
周期性的去霜也会在系统内引起热波动。与由于环境条件而引起的热波动不同，去霜周期所引起的热波动是由控制系统本身而不是由周围环境造成的。
与此相似，管理多个冷冻柜的控制系统能够引发很难预见的热波动。在一多柜系统内如果一旦所有柜都突然开动来满足它们各自的冷却需要，那么冷却容量必然快速跳升到最大。同样，如果所有柜都突然关停，那么冷却容量会相应猛降。但由于各该冷冻柜都可独立操作，因此冷却容量的瞬时需求将在大范围内不可预见地变化。
这些都是使有利于环保的系统的设计较为困难的问题。除了这些困难外，还有使用者的工程学/人机学的问题。今日的PID控制器可能难于适应分布的冷冻系统。有经验的控制工程师知道一个很好调谐的PID控制器在选择PID算法内使用的适当的控制常数时可能要一点技巧。在传统构造(未分布)的大冷冻系统内值得雇用一个控制工程师来巡视现场(也许反复进行)以便微调控制的恒定参数。
而在分布系统内，构成的部分各具有小得多的规模但部分的数目却很多，照老办法做便不切合实际。作为对比，一个传统的系统对整个多柜的、整店范围的系统可只采用一个控制器。而供同一店使用的分布系统要对店内的每一冷冻柜或相邻的一组冷冻柜设一控制器。分布系统需被设计得尽可能减少终端使用者的参预，因此最好将控制器设计成能自动调节的。而现有的控制系统缺乏这种能力。
本发明提供的分布冷冻系统系将冷凝器设置在冷冻柜上，用一特制的、脉冲宽度调节的压缩机来为它服务，该压缩机也可设在冷冻柜内。如果需要，冷凝器和压缩机可耦合在一起来为一组相邻的冷冻柜服务，每一冷冻柜各有自己的蒸发器。
脉冲宽度调节的压缩机采用两个机械元件如涡卷件，这两元件可相互相向转动，这样便可产生泵压致冷剂所需的流动压力。该压缩机包括一个机构可有选择地断开这两机械元件之间的密封，从而改变压缩机所产生的流体压力，同时允许这两机械元件基本上维持恒定的相互相对运动。造成和断开流体密封来调节压缩机的脉冲宽度时可不需开动和停止驱动这两机械元件的电动机。
脉冲宽度调节的压缩机是由一个控制系统根据测得的系统负载产生一个可变工作循环控制信号来驱动的。控制器还可调节控制信号的频率(或周期)来缩小在冷冻系统内的压力波动。开动时间因此等于工作循环数乘上周期，其时周期为频率的倒数。
本发明的冷冻系统具有许多优点。因为系统的瞬时容量很易用可变工作循环控制来调节，而偏大的压缩机在开动去霜和去霜后能被用来使温度更快地下降，不需造成短循环如同传统的压缩机系统那样。可变工作循环控制的另一个优点是系统能够很快地响应冷凝器温度或冷冻柜温度设定点的突然变化。控制器根据扰动来调节容量，不会产生不稳定的振荡，也不会有显著的过度超越。而且，使瞬时容量匹配需求的能力允许系统在较高的蒸发器温度下工作(传统的系统在超容量时所遇到的温度大幅降落的现象可以避免)。
在较高的蒸发器温度下工作可减少所需的去霜能量，因为系统在较高的温度下结霜较慢。而且，在各次去霜之间的时间能被延长一个累计运行时间的百分比，该百分比可由实际的可变工作循环控制信号规定。例如，一个百分之六十的工作循环可将各次去霜间的时间从标准的三小时增加到五小时(3/.60＝5)。
系统的脉冲宽度调节的操作能改善润滑油的返回。致冷剂在高容量和低容量(例如100％和0％)之间的脉动流动能造成较多的扰动，这种扰动能破坏润滑油在热交换器内的边界层。
可变工作循环控制系统的另一优点为其能用各种膨胀装置操作的能力，这些膨胀装置包括简单的孔眼、热膨胀阀(TXV)和电子膨胀阀。从膨胀装置控制器上导出的信号能被送到本发明的压缩机控制器上。这个信号允许可变工作循环控制信号及/或其频率能被调节到与膨胀装置的瞬时工作状态匹配。一个类似的方法可被用来操作空冷冷凝器系统中的速率可变风扇。在这种情况下本发明的控制器可根据压缩机的电流操作的工作循环提供一个信号来控制风扇速率。
本发明还有另一个优点是它能检测在什么时候系统内的所有致冷剂的装载量发生低落的现象，这是一个与环境有关的重要事情。偏低的致冷剂装载量能指示系统内存在着泄漏。当调节系统的工作循环时，观察实际温度与设定温度之间误差的变化便有可能检测出这种低装载量。因此可这样设计控制系统使它检测出在什么时候工作循环的调节没有收到所需的维持温度的效果。造成这现象可能是由于致冷剂装载量的漏失、堵塞的热膨胀阀或其他功能错误。
为了更完整地了解本发明的内容、目的和优点，请参阅下面的说明和附图。
附图的简要说明
图1为现有技术的冷冻系统配置的系统方块图；
图2为按照本发明的冷冻系统的方块图；
图3为脉冲宽度调节压缩机的一个实施例的横剖视图，所示为装载状态；
图4为图3中的压缩机的横剖视图，所示为卸载状态；
图5为按照本发明的冷冻或冷却系统的另一实施例；
图6为控制器的方块图；
图7为一方块图示出控制器如何可被用来调节一个蒸发器的分档调节器；
图8为图6中的控制器的信号调节组件的方块图；
图9为图6中的控制器的控制组件的方块图；
图10为画出控制器的操作状态的状态图；
图11为说明目前较优的PI控制算法的流程图；
图12为示出控制器所产生的可变工作循环信号和在恒定频率下的操作的波形图；
图13为示出在可变频率下操作的可变工作循环信号的波形图；
图14为将采用本发明的系统与传统设计的系统在温度和压力的动力学上比较的一系列的图解。
图15为说明本发明的自适应调谐组件的方块图；
图16a为一流程图示出自适应调谐组件的目前较优的操作，特别是在确定是否开始调谐上；
图16b为一流程图示出自适应调谐组件用积分模式完成的目前较优的过程；
图16c为一流程图示出自适应调谐组件用计算模式的操作；
图17为一状态图示出自适应调谐组件的各个操作状态；
图18为一方块图示出自适应调谐环的模糊逻辑方块；
图19为图18中的模糊逻辑方块的隶属函数图；
图20为图18中的模糊逻辑方块所使用的与图19中的隶属函数有关的真值表；
图21为图18中的模糊逻辑方块的输出隶属函数图；
图22为一略图示出为了完成本发明的与控制有关的和与检定有关的功能的传感器的示范位置。
较优实施例的说明
图1示出一个传统的超市冷冻系统。如前所述，传统的做法是将压缩机30和冷凝器32设置在远离冷冻柜34的地方。在本图中，压缩机30被设在建筑物的屋顶36上成为平行的排列。并排的压缩机供应一个大的可空冷或水冷的冷凝器32。冷凝器将液体致冷剂供到一个容器38内。该容器38又供应到各该并联的冷冻柜34内如图所示。在大多数装置中采用一个液体管线螺线管阀来调节流向相关蒸发器42的流量。致冷剂通过一个合适的膨胀装置如膨胀阀44供应到蒸发器内。膨胀阀44设有一个有限的孔眼用来使液体致冷剂雾化成液滴，然后被引到蒸发器42的进口侧。位在冷冻柜34内的蒸发器42从该柜及其内含物吸取热量将致冷剂液滴汽化成为气体。压缩机30抽吸这个气体并将它压缩返回成液态。然后液体致冷剂在冷凝器32内冷却并返回到容器38内，于是循环继续进行。
为了使冷却容量与负载匹配，可随需要单独或成组开动和关断压缩机30。在一典型的超市配置中可有数个如图1所示的独立系统来对付不同的操作温度范围。注意液体管线46和抽吸管线48都可能需要十分大的长度(例如可达150英尺)来跨越从冷冻柜到屋顶的距离。
图2所示的冷冻柜34是按本发明的原理设计的。冷凝器32和压缩机30都设在冷冻柜34内或装在其上。蒸发器42和相关的膨胀阀44也都设在柜34内。冷凝器32设有热量排除机构50用来将热量转移到周围空间内。热量排除机构可以是一个连接到合适管道上的水套用来将废热带到位在建筑物屋顶上的水冷塔内。或者，热量排除机构可以是一个强制风冷系统或一个不用电的对流空冷系统。
本发明的冷冻系统采用一个压缩机控制器52，它能将管线54上的脉冲宽度调节控制信号提供给压缩机30上的螺线管阀56。压缩机控制器使用下面将要说明的算法调节控制信号的脉冲宽度。有一合适的负载传感器如温度传感器58将输入信号提供给控制器以便用来确定脉冲宽度。
图3和4示出压缩机30的细节，图3示出的压缩机是在负载状态而图4所示是在卸载状态。当压缩机电动机保持接电时，螺线管阀56可使压缩机在这两个状态之间转换。这种设计的一个重要优点为压缩机能够很快地在负载和卸载两个状态之间调节脉冲宽度而可不需中断输向压缩机电动机的电力。这个脉冲宽度调节循环可使压缩机较少磨损，因为电动机不会突然改变其角动量。
参阅图3和4所示的示范压缩机30，该压缩机可采用气密的涡卷压缩机如同在受托人的美国专利5,102,316号中所说瞬的那种型式。
示范压缩机30包括一个外壳61和一个支承在上轴承壳体63上并通过曲柄销65和驱动轴衬60可驱动地连接到曲轴62上的转圈涡卷件64。第二个不转圈的涡卷件67的定位为与转圈涡卷件64啮合并在轴向上可移动地固定在上轴承壳体63上。有一分隔板69设在外壳61上端的附近用来在其上端形成一个排放室70。
操作时，随着转圈涡卷件64相对于涡卷件67而作的旋转运动，抽吸气体从抽吸进口71被引入外壳61内，然后通过设在不转圈涡卷件上的进口72进入到压缩机30内，设在涡卷件64和67上的互相啮合的麻花卷形成一个运动流体的凹窝，由于涡卷件64的旋转运动，这个凹窝的容积逐渐缩小并沿径向向内移动，这样就将通过进口72进来的气体压缩。于是压缩气体通过设在涡卷件67上的排放口73和通道74排放到排放室70内。
在要使压缩机30卸载时，螺线管阀56根据来自控制组件87的信号被驱动，这样便中断流体的连通，使室77内的排放气体的压力增加。由这个排放压力造成的偏压力将克服密封的偏压力，从而使涡卷件67沿轴向向上移动而离开转圈的涡卷件64。这个轴向运动在两个涡卷件64和67的各该麻花卷尖端和端板之间造成一条泄漏路径，从而基本消除抽吸气体的继续被压缩。
在一柔性管线91从通道90的外端延伸到一个通过外壳61伸出的配件92上，还有一条第二管线93将配件连接到螺线管阀56上。螺线管阀56设有流体管线82和84分别连接到抽吸管线83和排放管线85上，并都由控制组件87根据传感器88所感知的状态来控制，使不转圈的涡卷件67在图3和4所示的两个位置之间移动。
当要恢复对抽吸气体的压缩时，螺线管阀56将被驱动使涡卷件67移动到与涡卷件64密封接合。
图2的冷冻柜实施例可被组装成为独立的成套单元。虽然对许多用途需要这样做，但本发明并不仅限于这样做，而是致力于发展各种分布的冷冻系统，图5所示为这种系统的一例。
在一供暖、通风与供冷(HVAC)系统内，可用单一的压缩机和冷凝器来服务数个分布的冷冻柜或冷却单元。在图5中，冷冻柜或冷却系统壳体用虚线示出，如34a、34b和34c。顺便说一下，压缩机30和冷凝器32可被设置在其中一个冷冻柜内或壳体内如34a，或装在其上。
每一冷冻柜或壳体各有其自己的蒸发器和相关的膨胀阀如42(a、b、c)和44(a、b、c)。另外，每一冷冻柜或壳体可各有其自己的温度传感器58(a、b、c)以便将输入信息提供给压缩机控制器52。最后，有一个压力传感器60监控抽吸管线48的压力并将这个信息提供给压缩机控制器52。后者则将一个可变工作循环信号提供给螺线管阀56如前所述。
图5中的多柜或多个冷却单元的实施例示出单一的压缩机能被压缩机控制器52调节脉冲宽度以资供应对冷却的瞬时需求。温度传感器58(a、b、c)联合提供系统上的负载状态，如同压力传感器60的作用一样。控制器调节控制信号的脉冲宽度借以使压缩机在其高容量和低容量状态(100％、0％)之间调节以资满足对致冷剂的瞬时需求。
作为一个可替代的控制技术，在从蒸发器出来的一条或多条抽吸管线上可装备一个电动控制阀如蒸发器压力调节阀45c，阀45c被耦联到控制器52上如图所示，使该阀可得到适合于其型式的控制信号。步进电动机阀可用于这个目的，在该情况下控制器可提供一个合适的信号来使步进电动机的设定增量或减量从而调节阀的孔眼大小。或者，可用脉冲宽度调节的阀，在该情况下，它可用与提供给压缩机30相同的可变工作循环信号来控制。
控制器52并不限于只是用来控制压缩机。可变工作循环控制信号还可用来控制其他型式的致冷剂流量和压力控制装置如致冷剂调节阀。图7示出这种用途，其中控制器52的输出将控制信号提供给蒸发器分档调节器43。这个装置是一个由步进电动机45调节的流体调节器。蒸发器分档调节器(ESR)阀43调节抽吸压力，从而调节系统的容量。
目前较优的压缩机控制器的方块图在图6中示出。在这个和接续的图中示出的各种信号和数据值的说明现汇总在下面的表1中。
表1
 
序号 变数名称 缺席值 说明
1 信号调节：传感器报警、传感器模式取样时间(Ts)控制型式       假最小0.5秒T/P型式 指出传感器读数不在预期范围内使用者配置要求指出所有温度传感器是否已完成最小/最大/平均信号调节块以该速率执行是仅由温度控制还是由温度和压力两者控制                      
2 控制块：传感器报警系统报警SSL去霜状况降温时间增益(K)累积时间(Ti)控制时间(Tc)控制设定点(St)工作状态     假假0假0-710010秒OF1    同上由自适应块产生，指示存在某些系统问题稳定状态负载百分率系统是否在去霜去霜后降温所用时间在PI算法中使用的增益在PI中使用在PI中使用在PI中使用机械工作所在状态              
3 去霜控制：去霜状况去霜型式去霜间隔去霜延续去霜终止温度 假外部8小时1小时50F   冷柜是否在去霜去霜是以控制器的外部定时器还是以内部的时钟为准去霜之间的时间去霜延续时间去霜终止温度                  
在图6中，在控制器的心部为控制块组件102。这个组件负责在导线104上提供可变工作循环控制信号。组件102还在导线106上提供压缩机开/关ON/OFF信号及在导线108上提供工作状态指令信号。压缩机ON/OFF信号驱动电路闭合器以资将工作电流供给压缩机电动机。工作状态信号指出所述机械目前在什么工作状态。
控制块组件接受来自数个来源的输入，包括从上述温度和压力传感器来的温度和压力读数。这些温度读数通过信号调节组件110被输入，其详情在伪代码的附录中被示出。控制块组件还从去霜控制组件112接受去霜状况信号。去霜控制组件112含有逻辑电路可决定何时完成去霜。本实施例允许去霜的控制或是由外部逻辑信号(通过导线114提供)承担或是由去霜控制组件本身所产生的内部逻辑信号承担，采用哪一种方法可由使用者通过使用者输入116来选择。内部去霜控制采用使用者通过使用者输入118提供的参数。
较优的压缩机控制器的一种形式是能自动调节的。控制器包括一个可选用的自适应调谐组件120，该组件能根据系统的工作条件自动调节控制算法参数(比例常数K)。自适应调谐组件感知负载百分率(在导线104上)和工作状态(在导线108上)以及在信号调节后测得的温度(在导线122上)。组件120将自适应调谐参数提供给控制块102如图所示。本实施例能在导线124上提供比例常数K和在导线126上提供SSL参数，该参数指示稳定状态负载百分率。当系统不能像预期那样响应自适应调谐参数的变化时在导线126上的报警信号可警告控制块组件。因此当可能有系统误作用或丧失致冷剂装载量的现象时能发出报警信号。如果需要，这个报警信号能触发更复杂的常规检定程序。压缩机控制器还能提供多个使用者界面点，通过这些界面点可输入使用者提供的设定。去霜型式(内部/外部)输入116和内部去霜参数输入118已在前论述。另外还有使用者输入128可允许使用者在自适应调谐组件120上规定温度设定点。同样的信息也可通过使用者输入130供到控制块组件102上。使用者还能通过各种途径与控制块组件直接联系。使用者输入132允许使用者在去霜模式中拨动开关使压缩机开动或停止。使用者输入134允许使用者规定初始控制器参数，包括初始比例常数K。这个比例常数K可在以后被自适应调谐组件120修改。使用者输入136允许使用者规定压力导数(dP)使它被系统用来作为设定点。
除了这些使用者输入外，还设有一些使用者输入以便与信号调节组件110联系。使用者输入138可为信号调节组件选择传感器的工作模式，这点将在下面较详细地说明。使用者输入140允许使用者规定信号调节组件所用取样时间。使用者输入142允许使用者规定只是用温度传感器(T)还是温度和压力传感器都用(T/P)来操作控制器。
现在参阅图8，其中详细示出信号调节组件。输入(温度及/或压力传感器)144通过模拟-数字转换器(ADC)处理后然后供给控制型式选择器148。来自温度及/或压力传感器的温度读数被依次读取并连续通过模-数转换器供给。控制型式选择器将这些数据编码或存储使压力和温度值恰当地被判读。
然后在150对信号进行数字过滤以便去除不合逻辑的波动和噪声。接下来数据在组件152被校核以资保证所有读数都在预期的传感器范围限度内。这只要将用数码表示的数据转变为相应的温度或压力值并对照预先存储的传感器范围校核这些值便可做到。如果读数不在传感器的范围内便会产生报警信号在输出154上输出。
其次，在156完成数据的处理工作以便使温度及/或压力数据按传感器模式使用者输入所选择的形式供给。本实施例可有选择地将数据平均或确定数据的最小或最大值(Min/Max/Avg)。Min/Max/Avg模式可被用来计算压力微分的摆动或调节的温度值。平均模式可被用来提供调节的温度值。它们分别作为输出158和160被示出。
图9较详细地示出控制块组件。调节的温度或压力信号被送到计算组件162内，该组件计算在实际温度或压力与设定点温度或压力之间的误差。组件162还计算这些值的变化率。
控制块组件被设计成在周期的基础上(每隔Tc秒一次，正常为每秒一次)及时修正系统的工作状态。找寻工作状态组件164完成这个及时修正功能。图10的状态图告诉我们这是怎么完成的。基本上，工作状态是从一个状态进展到另一状态的，取决于是否有传感器报警(SA)存在、是否有去霜状况信号(DF)存在和计算出的误差值有多少。找寻工作状态组件164将工作状态参数和降温时间参数供给决定逻辑组件166。
参阅图10，找寻工作状态组件164如下从一状态进展到另一状态。从初始状态168开始，组件在初始化以后进展到正常工作状态170，并停留在该状态一直到遇上某些条件。图10用箭头示出需要什么条件从正常工作状态循环到去霜状态172；到降温状态174；到传感器报警降温状态176；到传感器报警工作状态178以及到传感器报警去霜状态180。
决定逻辑组件166(图9)确定可变工作循环信号的工作循环。这在导线182上输出，指出负载的百分率。决定逻辑组件还在导线184上产生使压缩机开/关的信号。实际的决定逻辑将在下面结合图11说明。决定逻辑组件是比例积分(PI)控制的一种形式，它是根据自适应计算的周期Tcyc来的。这个周期是由计算组件186根据组件188所产生的计算误差值计算出来的。返回参阅图6，在导线122上的调节的压力微分信号(Cond dp)连同通过使用者输入136提供的压力微分设定点值(图6)被供往计算误差组件188(图9)。在实际的和设定点的压力微分之间的差异由组件188计算出来并被送往计算组件186。自适应周期Tcyc为压力微分误差的函数，而由寻找工作状态组件164确定的工作状态可按下式计算：
Tcyc(新)＝Tcyc(旧)+Kc＊误差...........................(1)
其中Kc：比例常数
误差：(实际的-设定点的)抽吸压力摆动
决定逻辑组件166所使用的目前较优的PI控制算法在图11中示出。程序在工步200由读出使用者提供的参数K、Ti、Tc和St开始。这些使用者提供值的说明见图6。常数Kp被计算为等于初始提供值K；而常数Ki被计算为初始提供常数K和比率Tc/Ti的乘积。
其次，在工步202作出决定在设定点温度和调节的温度(图9，在导线190上)之间的误差的绝对值是否大于5％F。如果是，在工步204将常数Kp设定为等于零。如果否，程序简单地前进到工步206，在那里按照图11的工步206的等式计算新的负载百分率值。如果负载百分率大于100(工步208)，那么在工步210将负载百分率设定为等于100％。如果负载百分率不大于100％而是小于0％(工步212)，那么在工步214将负载百分率设定为0％。如果负载百分率在0％和100％的限度之间，那么在工步216将负载百分率设定为等于新的负载百分率。
控制器所产生的可变工作循环控制信号可采取数种形式。图12和13给出两个例子。图12所示的可变工作循环信号的工作循环是可变的，但频率保持恒定。在图12中注意由标记220指出的周期是相等的。作为比较，图13示出可变工作循环信号中频率也在变的情况。在图13中注意由标记220指出的间距并不相等，而是，波形出现频率恒定的区域、频率增加的区域和频率减少的区域。图13所示的可变频率是周期Tcyc进行自适应调节的结果。
图14图解地示出本发明的控制系统在保持较紧密的温度控制和较高的抽吸压力连同提高系统效率方面的优点。注意本发明的温度曲线222如何比传统控制器的相应温度曲线224具有相当小的波动。与此类似，注意本发明的压力曲线226具有一个远高于传统控制器的压力曲线228的底线。而且由本发明(曲线226)所展示的高峰到高峰的波动也比传统控制器的波动(曲线228)要小得多。
本发明的控制器的工作速率比负载的热时间常数至少为四倍那样快(典型的情况为至少约为八倍那样快)。在目前的较优实施例中，可变工作循环信号的周期比负载的时间常数约为八分之一那样短。拿非限定性的例子来说，可变工作循环信号的周期可能约为10到15秒，而被冷却的系统的时间常数可能约为1到3分钟。被冷却的系统的热时间常数一般为系统的物理的或热动力学的性能所限定。虽然有各种模型能被用来说明一个加热或冷却系统的物理的或热动力学的响应，但下面的分析将可指出其原理。
建立被冷却系统的热时间常数的模型
在一冷冻系统或作为第一级系统的热泵内人们能够模拟越过蒸发器蛇管的温度变化情况，其中温度的变化可用下列方程式来模拟：
ΔT＝ΔTss[1-exp(-t/r)]+ΔTo exp(-T/r)
其中ΔT＝越过蛇管的空气的温度变化
ΔTss＝越过蛇管的稳定状态空气的温度变化
ΔTo＝在时间为零时越过蛇管的空气的温度变化
t＝时间
r＝蛇管的时间常数
要得到该单元的瞬时容量可将上式乘上空气质量的流率(m)和在恒压下的比热(Cp)，然后对时间进行积分。
一般地说，这是从蒸发器内取走的致冷剂控制着要达到稳定状态的工作条件所需的时间，从而控制着越过冷凝器蛇管的稳定状态空气的温度变化。如果需要，该系统可用两个时间常数来模拟，其中一个根据蛇管的质量，而另一个根据将过多的致冷剂从蒸发器移到系统其余部分内所需的时间。另外，还可能需要考虑到，在某些系统内由于在蒸发器和冷凝器蛇管之间的实际距离大因而有时间滞后，进一步能延迟时间。
蒸发器蛇管的热响应可用下列方程式模拟：
θ＝1/2[(1-et/r1)+(1-et/r2)]
其中θ＝越过蛇管的温度变化/越过蛇管的稳定状态的温度变化
t＝时间
r1＝根据蛇管质量的时间常数
r2＝根据从蒸发器移走过多致冷剂所需时间的时间常数
实际上，本发明的控制器的循环速率显然比传统的控制器快。这是因为传统的控制器的开和关的循环是与实际和设定点的温度(或压力)比较直接联系的。换句话说，传统的控制器的循环是在需要冷却时开动，而当实际和设定点的温度之间的误差低于预定的限度时即关停。这样传统控制器的开和关的循环就非常高度地依赖于要被冷却系统的时间常数。
与此相反，本发明的控制器的开和关的循环是按计算值所规定的速率进行的，并不与实际和设定点的温度或压力之间的瞬时关系直接联系。而是，周期是由控制器所提供的循环速率和可变工作循环信号的工作循环两者规定的。值得注意的是，控制器在每一循环中从开变为关的点不一定是冷却需求得到满足的那一点，而是由需要满足需求的工作循环所规定的那一点。
自适应调谐
上述Geneva控制器能被设计用来完成经典的控制算法如传统的比例积分导数(PID)控制算法。在传统的设计中，使用者通常需要通过合适的编程来设定控制参数。而本发明采用的控制器则可像这里说明的自适应式那样，使用者可不需为确定适当的控制参数而操心。
这样，自适应控制器的一个重要优点是它有完成自适应调谐的能力。一般地说，调谐包括选择合适的控制参数使闭环系统能在工作条件的广阔范围内保持稳定，能迅速响应来减少扰动在控制环路上的影响，并且不会通过连续的循环引起机械构件的过分磨损。通常有多个互相排斥的判据，一般必须在它们之间作出折衷方案。在图18(还有图6)中有两个基本的控制环：冷冻控制环和自适应调谐环。冷冻控制环是由控制块组件102管理的；而自适应环是由自适应调谐组件120管理的。自适应调谐组件的细节在图15、16a-16c和17中示出。目前较优的自适应调谐组件采用模糊逻辑控制算法，该算法将结合图18到20予以说明。
参阅图15，自适应调谐组件基本完成三个功能。首先，它决定是否要完成自适应调谐。这由组件240来处理。第二，它收集所需的参数以便完成自适应调谐，这由组件242处理。第三，它计算被控制环使用的自适应增益，这由组件244处理。
组件240根据两个因素来决定是否要开始调谐：系统的电流工作状态和控制设定点。图16a的流程图示出包括在这个决定内的工步。组件242将组件244完成计算所需关键参数予以积分。基本上，组件242输入负载百分率、温度和压力值及设定点温度。它输出下列数据：S-ER(设定点值在0.5度或1psig内的调节温度和压力的数据点总数)，S-Close(在给定的取样区间如30分中负载百分率趋于0％的数据点总数)，S-Open(在取样区间内负载百分率趋于100％的数据点总数)和SSLP(在取样区间内负载百分率的移动平均或滚动平均)。组件242响应组件240所设定的调谐标记。当调谐标记发出信号时组件242就完成这些关键参数的积分，图16b示出其中包括的工步。
最后，计算块采用组件242提供的数据，利用图16c所示的过程计算自适应增益。
自适应调谐组件120将通过各种工作状态进行循环，这取决于定量器的状态。图17为一状态图示出目前较优的实施例是如何发挥其功能的。注意从初始模式到积分模式或非调谐模式的顺序转移取决于有无设定调谐标记。一旦进入积分模式，系统就完成积分一直到定时器走完(正常为30分钟)，于是进入计算模式。一旦计算完毕，就重新设定定时器，系统返回到初始模式。
自适应方案的方块图在图18中示出。有两个基本环，其一为PID控制环260，每dt秒运行一次，其二为自适应环262，每ta秒运行一次。
当控制系统开始时，PID控制环260采用一个增益(K)的缺席值来计算控制输出。自适应环262每隔ta秒266(最好小于0.2＊dt秒)校核一次误差e(t)264。在组件268如果误差的绝对值e(t)小于所需的偏差(os)，计数器的Er_new便被增加1。偏差(os)为可接受的稳定状态的误差(就温度控制言可为+/1℉)。这个校核过程继续tsum秒270(最好为dt秒的200到500倍)。在tsum秒270以后，将Er_new值转变为百分率(Er_new％272)。参数Er_new％272指示在tsum时间内在被取样的e(t)中误差在可接受的偏差(os)内的所占百分率。换句话说，这是对过去的tsum秒内控制变数被控制得好坏的一种衡量。100％的值意为严密的控制，而0％意为不良的控制。每当Er_new％为100％时，增益可基本上保持不变，因为它指示较严的控制。但当Er_new在0和100％之间时，便可用自适应模糊逻辑算法组件274来计算新的增益(K_new 276)，然后由控制算法组件278使用该增益来为下一个tsum秒进行计算。
在较优的实施例中，模糊逻辑算法组件274有一个输出和两个输入。该输出为使用输入Er_new％和一个变数Dir计算出来的新的增益，Dir的定义如下：
Dir＝Sign[(Er_new％-Er_old％)＊(K_new-K_old)]...(2)
其中Sign为括号内项目的符号(+ve、-ve或零)；
Er_new％为在过去的tsum秒内在偏差内的e(t)％；
Er_old％为在(tsum-1)循环内Er_new％的值；
K_new为在tsum时间内使用的增益；
K_old为在(tsum-1)时间内的增益。
例如，假定控制器在0秒开始，缺席值k＝10，ta＝1秒，tsum＝1000秒，os＝1。假定从一个可能为1000数据中出来的600e(t)数据在偏差范围内。因此，在1000秒以后，Er_new％＝60(即600/1000＊100)，K_new＝10。在初次使用自适应模糊逻辑算法时可将Er_old％和K_old设定为零。将这些数值代入方程式(2)得出变数Dir的符号为正。因此，自适应模糊逻辑算法组件274在第一循环的输入分别为Er_new％＝60和Dir为正值(Dir＝+ve)。
下一工步是要使用隶属函数将这些输入模糊化使它们成为模糊输入。
模糊化
隶属函数是一个在论述的事物(x轴)和等级空间(y轴)之间的图象。论述的事物为输入或输出的各种可能值的范围。对于Er_new％最好为0到100。等级空间值通常为0到1并被称为模糊输入、真值或隶属程度。图19所示图象300含有输入Er_new％的隶属函数，Er_new％被划分成为三个语言变数即大Large(304)、中Medium(306)和小Small(308)。对于Er_new％＝60，模糊输入(或隶属函数的程度)为大0.25和中0.75。输入变数Dir已被很好定义为(+、-或0)，因此在这应用上不需隶属函数。下一工步为编制真值表或规则评估。
规则评估
规则评估从模糊化工步取得模糊输入并利用以知识为基础的规则计算模糊输出。图20示出成为真值表的规则。对于第一行和第一列，规则为“如果Er_new％为大并且Dir为负，那么新的增益不变(NC)(即如果在过去的tsum秒内在(os)范围内的e(t)数据的百分率为大并且方向(Dir)为负/零，那么现有K值不变(NC)。
在本例中，由于Er_new％具有模糊输入大(0.25)和中(0.75)及正的Dir，适用的规则将是：
如果Er_new％为大(0.25)而Dir为正，那么新的增益不变(NC＝1)
如果Er_new％为中(0.75)而Dir为正，那么新的增益为正的小改变(psc＝1.2)
解除模糊化
最后为解除模糊化过程，使用图21的图解将来自规则评估工步的模糊输出转变为最终输出。图解310采用下列标记：NBC为负的大改变；NSC为负的小改变；NC为不变；PSC为正的小改变；PBC为正的大改变。在较优实施例中采用重心或矩心法来解除模糊化。用来转变成增益的输出的隶属函数在图21中示出。
矩心(模糊逻辑输出)可如下计算：
矩心＝K_new
其 中μ(x)为所论述事物值x的模糊输出值
在本例中，输出(K_new)为
Figure C200510064860D00231
一旦三个工步，即模糊化、规则评估和解除模糊化都已完成，输出也被计算出来，就可为Er_new％的新的设定再一次重复上述过程。
在上例中，在第一个1000秒以后，自适应算法计算出新的增益为K_new＝11.50。这个新的增益被PID环用于下一个1000秒(即实时地从t＝1000到2000秒)。在t＝1001秒时将计数器Er_new设定为零以便完成下一个1000秒的计数。在另一个1000秒终止时(即在t＝2000秒时重新计算Er_new％。
假定这时Er_new％为25。这意味着将K从10改变到11.5，控制反而变坏。因此最好在另一方向上改变增益，即减少增益而不是增加增益。这样，在t＝2000秒时，Er_new％＝25，Er_old％＝60(Er_new％以前的值)，K_new＝11.5和K_old＝10(以前的K值)。应用方程式(2)，得到负的Dir值。使用25的Er_new％和负的Dir，重新进行模糊逻辑计算，算出下一个1000秒的新的获得。新的获得值为K_new＝7.76并被PID环用于从t＝2000到3000秒。
假定第三次循环即从t＝2000到3000秒，Er_new％得出为95％(这代表较严密的控制)。进行相同的模糊逻辑运算给出相同的K_new值，这时获得保持不变一直要到Er_new％重新恶化。
示范的应用
脉冲宽度调节(PWM)压缩机和电子分档调节器(ESR)阀都可用来控制蒸发器的温度/压力或蒸发器冷却流体(空气或水)的温度。前者通过调节致冷剂的流量来控制，而后者则限制抽吸侧来控制流量。参阅图18，其中示出在冷冻系统279中工作的这种驱动器的控制系统的方块图。在图18中每隔dt秒对一个或较好是对四个蒸发器冷却流体的温度或对一个蒸发器的抽吸压力(一般地在282示出)取一次样。dt＝10秒的取样管线对这两个用途都很合适。在被模拟到数字组件284处理后，在组件286根据系统的设计或使用者的意愿，从四个温度中采取平均或最小或最大，将取样的信号减少到一个。通常，在一个单一驱动器(PWM/ESR)的系统中，整个蒸发器蛇管都是同时进行去霜的，这时采取控制信号的平均值较佳。而在多个蒸发器一个驱动器的系统中，蒸发器各蛇管的去霜并不同时进行，这时采用最小值是较佳的模式。在平均/最小/最大后得到的值被称为调节的信号。在比较组件288将这个值与所需的设定点比较，计算出误差e(t)。
在环路中采用的控制算法为比例积分(pI)控制技术(PID)。PI算法计算出ESR的阀门位置(O-100％)或在PWM压缩机的情况下计算出负载百分率(0-100％)。对这两种情况的驱动器，典型的整个重新设定时间都是60秒。增益被自适应环合适地调谐。在较优实施例中，每当遇到下述情况都应停止进行自适应算法：系统在去霜；正在通过降温阶段；有一个大的设定点变动；检测出传感器失效或任何一个其他系统失效。
因此，自适应算法通常是当系统在正常模式下工作时用的。较好使用的时间ta约为1秒而tsum约为1800秒(30分)。
与PWM压缩机/ESR阀有关的诊断方法
参阅图22，一个排放冷却流体的温度传感器312(Ta)、一个蒸发器蛇管进口温度传感器314(Ti)和一个蒸发器蛇管出口温度传感器316(To)能为采用PWM/ESR的蒸发器控制提供能诊断的特点。进口温度传感器314可设在蒸发器蛇管内的任何地方。但较好的位置是在从蒸发器蛇管分配器320起算的蒸发器的总长度的约三分之一处。
采用这三个温度传感器能够得到对系统的认识，这些认识能被用来诊断。例如当将ESR/PWM用于一个单一的蒸发器和膨胀阀时可每隔tsum秒在自适应环路上跟踪下列变数。这些变数可在自适应环路上Er_new正好被积分后进行积分。
N-Clase：阀门位置/PWM负载为0％时的次数。
N-Open：阀门位置/PWM负载为100％时的次数。
MAVP：tsum秒内阀门位置/PWM负载的移动平均。
SSLP：稳定状态的阀门位置/PWM负载。如果在tsum时间内Er_new％大于50％，将SSLP设定为等于MAVP。
dT：Ta和Ti之间差异(Ta-Ti)的移动平均。
SH：在所说时间内To和Ti之间差异(To-Ti)的移动平均。这大致为蒸发器的过热。
N-FL：在所说时间即tsum秒内To小于Ti的次数。这数指示膨胀阀有多少次淹没蒸发器。
另外，在去霜后降温的时间也被获知。根据这些变数，可作下列诊断：温度传感器失效、膨胀阀恶化、ESR阀/PWM压缩机恶化、ESR/PWM过大、ESR/PWM过小和没有空气流动。
温度传感器失效
可校核温度读数是否在预期范围内来检测温度传感器的失效。如果用Ta作为控制变数来控制PWM/ESR，那么当Ta失效时，可如下进行控制。上述驱动器可根据Ti或根据利用dT估计出来的Ta值(即将dT加到Ti值上)来控制。在已知的降温时间(tpd)内，阀门/PWH可被设定为完全开放/负载。如果Ti也已同时失效或无法取得，那么在降温时间内，驱动器可100％打开，然后在降温时间之后被设定为稳定状态负载百分率(SSLP)。在这种情况下须向机长报警。
膨胀阀恶化
如果膨胀阀粘住或失调或过小/过大，那么可用下列跟踪变数的组合来诊断这类问题。N_FL>50％和Er_new％>10％时指示膨胀阀粘住在开启状态或失调或者甚至过大以致淹没蒸发器蛇管。在这种情况下须报警。另外，SH>20和N_FL＝0时指示膨胀阀失调或阀门过小或阀门粘住在关闭状态。
ESR阀/PWM压缩机恶化
恶化的ESR表现在遗漏工步或被粘住，恶化的PWM压缩机表现在其螺线管阀被粘住在闭合或开启状态。在去霜是将ESR/PWM设定为0％来完成的配置中，这些问题可如下被检测出来。
如果在去霜前Er_new％>50％，而在去霜时Ti<32℉及SH>5℉，那么该阀被确定为遗漏工步。因此，该阀被关闭按另一个100％运行，如果Ti和SH保持相同，那么这就高度表明该阀已被粘住。
如果Er_new％＝0，N_Close为100％，而Ti<32℉，SH>5℉，那么PWM/ESR被确定为粘住在开启状态。如果Er_new％＝0，N_Open为100％，而Ti>32℉，SH>5℉，那么PWM/ESR被确定为粘住在关闭状态。
ESR/PWM过大
如果N_Close>90％而30％<Er_new％<100％，那么应为阀门/PWM压缩机过大报警。
ESR/PWM过小
如果N_Open>90％而Er_new％＝0，SH>5，那么应为阀门/PWM压缩机过小报警。
没有空气流动
如果N_Open＝100％，Er_new％＝0，SH<5℉，而Ti<25℉及N_FL>50％，那么或是空气被堵塞，或是风扇没有很好工作。
另外，这些诊断策略也可用于电子膨胀阀控制器。
上述这些实施例都是为了说明的目的，并不要用来限制本发明。对本行业的行家来说，在不离开所附权利要求所限定的本发明的精神和范围的条件下，是很容易对说明书内论述的本发明的实施例作出各种改变和修改的。
附录
完成信号调节的伪代码
每隔Ts秒重复下列项目一次：
读出使用者输入：
取样时间(Ts)
控制型式(P或T)
传感器模式(Avg/Min/Max)
完成模拟到数字的转换(ADC)
在所有(四个)温度传感器的通道上输出统计的数据
数字过滤统计
Ynew＝0.75＊Yold+0.25*统计(Y为增益)
输出过滤统计的数据
将过滤统计转换成℉
试验是否至少有一个传感器在正常工作范围内
例如在-40和+90℉之间
如果没有一个在该范围内-设定传感器报警为真
否则根据传感器模式完成Avg/Min/Max操作
如果控制型式不是T/P控制型式
那么终止信号调节常规程序(一直到下一个Ts周期)
否则(控制型式为T/P)进行下列程序：
在压力传感器通道上完成ADC
输出统计的数据
数字过滤统计
Ynew＝0.75＊Yold+0.25＊统计
输出过滤统计的数据
将过滤统计转换成Psig
试验压力传感器是否在正常操作范围内
例如在0和+200之间
如果不在范围内，设dP＝dP设定点
否则：计算dP＝Pmax-Pmin
设定时调节T/dP的传感器报警
终止信号调节常规程序(一直到下一个Ts周期)

Claims (18)

1.一压缩机控制系统，它包括：
一用于将气体从抽吸压力压缩至排放压力的涡卷压缩机，上述压缩机包括互相啮合的涡卷包络面，后者限定了移动的流体腔，上述涡卷包络面可彼此相对地运动，以产生压力并压缩上述气体；
一提供指示系统温度的温度信号的温度传感器；
一控制机构，它在操作上与上述互相啮合的涡卷包络面接合，以产生压力，同时保持上述涡卷包络面的基本恒定的相对运动；以及
一控制器，它操作上述控制机构，并响应上述温度信号，提供一可变的工作循环控制信号，以用于根据上述温度信号调制上述涡卷压缩机的工作容量，当上述可变工作循环控制信号的调制对上述系统温度不具有预定的作用时，上述控制器确定一系统功能错误。
2.如权利要求1的控制系统，其特征为，上述控制机构包括一电磁阀，上述电磁阀按一脉冲宽度调制方式接电，以操纵上述互相啮合的涡卷包络面，以改变所产生的上述压力。
3.如权利要求1的控制系统，其特征为，上述互相啮合的涡卷包络面限定一流体室，上述流体室有选择地与上述抽吸压力和上述排放压力中的一个连通，以调制上述涡卷压缩机的上述工作容量。
4.如权利要求3的控制系统，其特征为，上述控制机构包括一用于控制向上述流体室的流体流动的电磁阀。
5.如权利要求1的控制系统，其特征为，上述可变的工作循环控制信号的循环周期比施加至上述涡卷压缩机的负载的时间常数短。
6.如权利要求1的控制系统，其特征为，上述可变的工作循环控制信号是脉冲宽度调制的信号。
7.如权利要求6的控制系统，其特征为，上述脉冲宽度调制的信号的循环周期比施加至上述涡卷压缩机的负载的时间常数短。
8.如权利要求1的控制系统，其特征为，上述系统功能错误是低的致冷剂装载量或堵塞的热膨胀阀。
9.一控制系统，它包括：
一第一壳体；
一设置在上述壳体中的第一蒸发器；
一与所述第一蒸发器流体连通的冷凝器；
一按流体连通与上述第一蒸发器和上述冷凝器结合的压缩机，上述压缩机可以操作成将气体从抽吸压力压缩成排放压力，上述压缩机包括一脉冲宽度调制的变容量涡卷压缩机，后者有限定移动的流体腔的互相啮合的涡卷包络面，上述涡卷包络面可彼此相对地运动，以产生压力并压缩上述气体；
一提供指示系统温度的温度信号的温度传感器；
一控制机构，它在操作上与上述互相啮合的涡卷包络面接合，以产生上述压力，同时保持上述涡卷包络面的基本恒定的相对运动；以及
一控制器，它操作上述控制机构，并响应上述温度信号，提供一可变的工作循环控制信号，以用于根据上述温度信号调制上述涡卷压缩机的工作容量，当上述可变工作循环控制信号的调制对上述系统温度不具有预定的作用时，上述控制器确定一系统功能错误。
10.如权利要求9的控制系统，其特征为，上述控制机构包括一电磁阀，上述电磁阀按一脉冲宽度调制方式接电，以操纵上述互相啮合的涡卷包络面，以改变所产生的上述压力。
11.如权利要求9的控制系统，其特征为，上述互相啮合的涡卷包络面限定一流体室，上述流体室有选择地与上述抽吸压力和上述排放压力中的一个连通，以调制上述涡卷压缩机的上述工作容量。
12.如权利要求11的控制系统，其特征为，上述控制机构包括一用于控制向上述流体室的流体流动的电磁阀。
13.如权利要求9的控制系统，其特征为，它进一步包括一具有一设置在其中的第二蒸发器的第二壳体，上述第二壳体按流体连通与上述冷凝器结合。
14.如权利要求9的控制系统，其特征为，它进一步包括一具有一设置在其中的第二蒸发器的第二壳体，上述第二蒸发器按流体连通与上述压缩机结合。
15.如权利要求9的控制系统，其特征为，上述可变的工作循环控制信号的循环周期比施加至上述涡卷压缩机的负载的时间常数短。
16.如权利要求9的控制系统，其特征为，上述可变的工作循环控制信号是脉冲宽度调制的信号。
17.如权利要求16的控制系统，其特征为，上述脉冲宽度调制的信号的循环周期比施加至上述涡卷压缩机的负载的时间常数短。
18.如权利要求9的控制系统，其特征为，上述系统功能错误是低的致冷剂装载量或堵塞的热膨胀阀。
CNB2005100648602A 1997-09-29 1998-09-09 采用脉冲宽度调节工作循环的涡卷压缩机的冷冻系统的自适应控制 Expired - Fee Related CN100513791C (zh)

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US08/939,779 US6047557A (en) 1995-06-07 1997-09-29 Adaptive control for a refrigeration system using pulse width modulated duty cycle scroll compressor
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