Fail safe electronic pressure switch for compressor motor

[0002] This invention relates to an electronic switch for stopping operation of a compressor motor if certain pressure conditions are not met.

[0003] Compressors are typically driven by an electric motor to compress a fluid, such as a refrigerant, and move that fluid to a downstream use. In a refrigerant compressor, typically, the compressed refrigerant is sent into a refrigerant cycle.

[0004] In a refrigerant compressor, there are many potential concerns that can arise. As one example, the refrigerant can be over pressured due to a number of conditions. For that reason, pressure sensors have typically been incorporated somewhere adjacent the discharge portion of the compressor to monitor the discharge pressure. If the discharge pressure exceeds a predetermined amount, then the compressor motor may be stopped. Typically, these pressure sensors have included mechanical elements that move against a spring force, etc., to open a cutoff switch.

[0005] While a mechanical switch is relatively inexpensive, it is not as reliable as would be desired. Thus, a more reliable safety switch with fail-safe features would be desirable.

[0006] In the disclosed embodiment of this invention, a pressure sensor communicates with an electronic control to send a signal to a switch to stop operation of a compressor motor should a sensed pressure be outside an acceptable range. Most preferably, the pressure sensor is sensing a discharge pressure, and the condition which is outside the acceptable range would typically be an overly high discharge pressure.

[0007] In the disclosed embodiment, a microprocessor based control receives a voltage signal from a pressure sensor which is related to the compressor discharge pressure. A transducer is typically included into the electronic pressure sensor such that the pressure is transferred into a related voltage amount. The voltage amount is sensed by the microprocessor based control. If the voltage amounts indicates that the pressure exceeds a particular predetermined high pressure, then a signal is sent to a first switch to stop operation of the compressor. Most preferably the compressor is stopped by opening a relay which is part of the compressor motor control.

[0008] Such a system provides benefits when compared to the prior art. However, with such an electronically controlled system it would still be desirable to include a fail-safe mode to ensure proper operation of the electronic control. Thus, in a most preferred embodiment, the signal from the pressure sensor, which is preferably a voltage signal, is sent to a comparing circuit. The comparing circuit sends a signal to a second switch. If the comparing circuit senses that the pressure voltage signal is less than, or more than, predetermined boundaries, then the relay is left open. The compressor motor is again stopped from operating. In this way, should the microprocessor or pressure sensor fail, this fail-safe portion of the circuit will stop operation of the motor.

[0009] In a preferred embodiment, the first switch, which communicates with the microprocessor based control is a triac. The second switch is preferably an output relay. The second switch relay is preferably in series with the triac, and is controlled by the comparing circuit. The comparing circuit is preferably a bandwidth comparing circuit.

[0010] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.

[0011] The sole FIGURE is a schematic view of a circuit for controlling a compressor motor.

[0012] As shown in FIG. 1 a compressor 20 includes a pump unit 22 driven by a motor 24. A motor relay 26 may be deactivated to stop operation of the compressor motor 24 through a safety circuit 28. The pump unit 22 is shown as a scroll compressor, but this invention extends to any type of compressor. In a disclosed embodiment a AC power source 30 is part of the circuit 28 and supplies power to a first switch 32. The first switch 32 is preferably a triac receiving an input from AC power source 30, and a second input from a microprocessor 34, as will be described below. The output of the triac extends to a second switch 36. The switch 36 is preferably a relay which communicates power to the motor relay 26. As shown, a comparing circuit 40 receives two inputs 42 and 44. The input 42 compares a voltage from a pressure sensor V_pto the max value. If the V_pexceeds the V max value then a signal is sent to an OR gate 45. The second input 44 of the circuit compares to V_pto a minimum value. If the V_pvalue is less than the V minimum, then a second signal is sent to the OR gate 45. If the output of the gate 45 is that either 42 or 44 indicates a problem, then the relay switch 36 opens the relay 24. The effect of the combined circuit 40 is to ensure that the V_pis at least equal to a minimum value, and is less than a maximum value.

[0013] The V_pvalue is sent also to the microprocessor 34. In the microprocessor 34, the V_pvalue is compared to system condition, and a signal is sent to the triac 26 if the V_pvalue exceeds a predetermined maximum. The predetermined maximum by the microprocessor is typically less than the V max value. The portion 40 of the circuit is intended as a fail-safe component to ensure that the pressure sensor 50 and the microprocessor based control are operating properly. If the V_pvalue is not within the range of the comparing circuit 40, and yet the microprocessor has not stopped operation of the motor through the triac 28, there is some indication that either the pressure sensor 50 or the microprocessor control itself have failed. Thus, the comparing circuit 40 will operate to stop the compressor.

[0014] The pressure sensor 50 may be as known, and is shown on a discharge pressure of the compressor pump unit 22. Typically, the pressure sensor senses the pressure and transforms that pressure into a voltage which is relative to the pressure.

[0015] The present invention discloses a low cost effective fail-safe design for incorporating electronic controls into a compressor pressure sensor. A worker of ordinary skill in the art would recognize how to provide the particular software and hardware. It is not the design of any one component which is inventive here, but rather the combination of the components to achieve the benefits as set forth in the following claims which is inventive. Moreover, a worker in this art would recognize that there would be many modifications within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.