U.S. patent application number 14/076716 was filed with the patent office on 2014-03-06 for system and method to position variable diffuser vanes in a compressor device.
This patent application is currently assigned to Dresser, Inc.. The applicant listed for this patent is Dresser, Inc.. Invention is credited to Dale Eugene Husted, Marc Gavin Lindenmuth.
Application Number | 20140064919 14/076716 |
Document ID | / |
Family ID | 50187848 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140064919 |
Kind Code |
A1 |
Husted; Dale Eugene ; et
al. |
March 6, 2014 |
SYSTEM AND METHOD TO POSITION VARIABLE DIFFUSER VANES IN A
COMPRESSOR DEVICE
Abstract
Embodiments of a system and method can modify the position of
diffuser vanes to improve performance of a compressor device, e.g.,
a centrifugal compressor. These embodiments include a feedback loop
to manage the position of the diffuser vanes relative to one or
more operating characteristics of an actuator that imparts movement
to the diffuser vanes. In one embodiment, the system and method
measure the operating characteristic for the actuator with the
diffuser vanes at a first position and a second position. The
system can compare values for the operating characteristics,
wherein changes in the operating characteristic can identify other
positions for the diffuser vanes to reduce input power the actuator
consumes to move and/or maintain the position of the diffuser
vanes. This feature can correlate with optimal performance of the
compressor device and with peak compressor efficiency within the
entire operating envelope of the compressor device.
Inventors: |
Husted; Dale Eugene;
(Centerville, IN) ; Lindenmuth; Marc Gavin;
(Atlanta, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dresser, Inc. |
Addison |
TX |
US |
|
|
Assignee: |
Dresser, Inc.
Addison
TX
|
Family ID: |
50187848 |
Appl. No.: |
14/076716 |
Filed: |
November 11, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13601713 |
Aug 31, 2012 |
|
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14076716 |
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Current U.S.
Class: |
415/17 |
Current CPC
Class: |
F04D 27/00 20130101;
F04D 29/464 20130101; F04D 27/0246 20130101 |
Class at
Publication: |
415/17 |
International
Class: |
F04D 27/00 20060101
F04D027/00 |
Claims
1. A system, comprising: a compressor device comprising an
impeller, a diffuser vane in flow connection with the impeller, and
an actuator coupled with the diffuser vane; and a controller
coupled to the compressor device, the controller comprising a
processor having access to executable instructions stored on memory
and configured to be executed by the processor, the executable
instructions comprising instructions for: receiving a first input
comprising data for a first value of an operating characteristic
for the actuator with the diffuser vane in a first position;
receiving a second input comprising data for a second value of the
operating characteristic for the actuator with the diffuser vane in
a second position; comparing the first value and the second value;
selecting an increment by which to move the diffuser vane from the
second position, the increment defining the relative position of
the second value with respect to the first value; and generating an
output comprising data to instruct the actuator to move the
diffuser vane from the second position by the increment.
2. The system of claim 1, wherein the operating characteristic
identifies input power to the actuator.
3. The system of claim 1, wherein the operating characteristic
correlates with flow characteristics about the diffuser vane.
4. The system of claim 1, wherein the actuator comprises a linear
actuator.
5. The system of claim 4, wherein the linear actuator is configured
to operate in response to an electrical input.
6. The system of claim 4, wherein the linear actuator is configured
to operate in response to a pneumatic input.
7. The system of claim 1, wherein the executable instruction
comprise instructions for determining an inlet flow value upstream
of the impeller and setting the first position to correspond with
the inlet flow value.
8. The system of claim 7, further comprising a flow meter disposed
upstream of the impeller, the flow meter providing a third input
that comprises data that reflects the inlet flow value, wherein the
executable instruction comprise instructions for receiving the
third input and instructing the actuator to move the diffuser vanes
to the first position.
9. The system of claim 1, wherein the increment changes the
position of the diffuser vane in a first direction if the second
value is larger than the first value, wherein the increment changes
the position of the diffuser vane in a second direction if the
second value is smaller than the first value, and wherein the first
direction is different from the second direction.
10. The system of claim 1, wherein the executable instructions
comprise instructions for comparing the second value to a threshold
criteria, wherein the threshold criteria defines a maximum value
for the operating parameter and a minimum value for the operating
parameter, and wherein the increment changes the position of the
diffuser vane if the second value is equal to or greater than the
maximum value and equal to or less than the minimum value.
11. The system of claim 1, wherein the diffuser vane has a leading
edge and a trailing edge, and wherein the diffuser vane rotates
about an axis proximate the leading edge.
12. The system of claim 1, wherein the increment defines an angular
offset of the diffuser vane from the second position.
13. A compressor device, comprising: a drive unit; an impeller
coupled to the drive unit; a diffuser assembly in flow connection
with the impeller, the diffuser assembly comprising a diffuser vane
an actuator coupled to the diffuser vane and configured to move the
diffuser vane; and a controller coupled with the actuator, the
controller comprising a processor with access to executable
instructions configured to be executed by the processor and stored
on memory, the executable instructions comprising instructions for:
receiving a first input with data that relates to a first value for
an operating characteristic for the actuator with the diffuser vane
in a first position; receiving a second input with data that
relates to a second value for the operating characteristic for
actuator with the diffuser vane in a second position; comparing the
first value and the second value; selecting an increment by which
to move the diffuser vane from the second position, the increment
defining the relative position of the second value with respect to
the first value; and generating an output comprising data to
instruct the actuator to move the diffuser vane from the second
position by the increment.
14. The compressor device of claim 13, further comprising a
parameter sensor coupled with the controller, wherein the parameter
sensor is in position to measure flow of a working fluid.
15. The compressor device of claim 14, wherein the parameter sensor
measures input power to drive the actuator.
16. The compressor device of claim 15, wherein the actuator
comprises a pneumatic cylinder.
17. The compressor device of claim 15, wherein the actuator
comprises a motor to generate movement of the diffuser vane from
the second position.
18. The compressor device of claim 13, wherein the diffuser vane
leading edge, a trailing edge, and a rotation axis proximate the
leading edge, and wherein the trailing edge rotates about the
leading edge when moving from the first position and the second
position.
19. A computer program product for improving efficiency of a
compressor device, the computer program product comprising a
computer readable storage medium having executable instructions
embodied therein, wherein the executable instructions comprise one
or more executable instructions for: receiving a first input with
data that relates to a first value for an operating characteristic
for an actuator coupled with a diffuser vane in a first position;
receiving a second input with data that relates to a second value
for the operating characteristic for the actuator with the diffuser
vane in a second position; comparing the first value and the second
value; selecting an increment by which to move the diffuser vane
from the second position, the increment defining the relative
position of the second value with respect to the first value; and
generating an output comprising data to instruct the actuator to
move the diffuser vane from the second position by the
increment.
20. The computer program product of claim 19, wherein the
executable instructions comprise instructions for comparing the
second value to a threshold criteria, wherein the threshold
criteria defines a maximum value for the operating parameter and a
minimum value for the operating parameter, and wherein the
increment changes the position of the diffuser vane if the second
value is equal to or greater than the maximum value and equal to or
less than the minimum value.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 13/601,713, filed on Aug. 21, 2012, and
entitled "System and Method to Improve Performance of a Compressor
Device Comprising Variable Diffuser Vanes." The content of this
application is incorporated by reference herein in its
entirety.
BACKGROUND
[0002] The subject matter disclosed herein relates to compressor
devices with particular discussion that concerns use of diffusers
and diffuser vanes on a centrifugal compressor.
[0003] Centrifugal compressors and related compressor devices often
use a diffuser assembly to convert kinetic energy of a working
fluid into static pressure. In theory, the assemblies orient one or
more diffuser vanes to slow the velocity of the working fluid
through an expanding volume region. An example of the diffuser
assembly arranges several diffuser vanes circumferentially about an
impeller. The design (e.g., shapes and sizes) of the diffuser
vanes, in combination with the orientation of the leading edge and
the trailing edge of the diffuser vanes with respect to the flow of
the working fluid, can determine how the diffuser vanes affix
within the diffuser assembly.
[0004] In some compressor devices, the diffuser assembly
incorporates variable diffuser vanes, which can move (e.g. rotate)
during operation of the compressor device. This degree-of-freedom
improves the design and flexibility of the compressor device to
adapt to working conditions, e.g., changes in flow rate of the
working fluid. For example, the variable diffuser vanes can move to
change the orientation of the leading edge and the trailing edge to
tune operation of the compressor device. Known designs for variable
diffuser vanes rotate about an axis that resides in the lower half
of the diffuser vanes, i.e., closer to the leading edge than the
trailing edge.
BRIEF DESCRIPTION OF THE INVENTION
[0005] This disclosure presents embodiments of systems and methods
that can modify orientation of variable diffuser vanes to improve
performance of a centrifugal compressor and related compressor
devices. The embodiments manage the position of the diffuser vanes
relative to operating characteristics associated with the diffuser
assembly. In one embodiment, a controller couples with an actuator
to collect data that relates to operation of the actuator to
position the diffuser vane during operation of the compressor
device. The data can reflect, for example, input power the actuator
requires to move the diffuser vanes between a first position and a
second position. The controller can compare the data to identify
the change in the operating characteristics that occurs, if at all,
when the diffuser vanes move between the first position and the
second position. In one embodiment, the controller can generate an
output in response to changes in the operating characteristic to
move the diffuser vane to a third position. The controller can
collect data about the operating characteristic at this third
position and, subsequently, use the data to identify any change in
operation of the actuator with the diffuser vanes in the third
position. For example, pressure the working fluid imparts on the
diffuser vanes in the third position may balance across the
diffuser vanes, thus reducing the input power that the actuator
requires to maintain the diffuser vanes in the third position. This
reduction in input power can indicate that the diffuser vanes are
in an optimal position for operation of the compressor devices. In
some embodiments, the process of moving the diffuser vanes among
positions continues to optimize performance of the compressor
device, e.g., to reduce power consumption and to achieve and
maintain peak compressor efficiency within the entire operating
envelope for the compressor device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Reference is now made briefly to the accompanying drawings,
in which:
[0007] FIG. 1 depicts a front, perspective view of an example of a
compressor device;
[0008] FIG. 2 depicts a back, perspective view of the compressor
device of FIG. 1;
[0009] FIG. 3 depicts a schematic diagram of an exemplary
embodiment of a system for controlling operation of a compressor
device, e.g., the compressor device of FIGS. 1 and 2;
[0010] FIG. 4 depicts a flow diagram of an exemplary embodiment of
a method for operating a compressor device, e.g., the compressor
device of FIGS. 1 and 2;
[0011] FIG. 5 depicts a top view of the exemplary diffuser vane in
a first position and a second position for use in a compressor
device, e.g., the compressor device of FIGS. 1 and 2;
[0012] FIG. 6 depicts a top view of the exemplary diffuser vane of
FIG. 5 in a first position, a second position, and a third
position; and
[0013] FIG. 7 depicts a high-level wiring schematic of an example
of controller for use in a system, e.g., the system of FIG. 3.
[0014] Where applicable like reference characters designate
identical or corresponding components and units throughout the
several views, which are not to scale unless otherwise
indicated.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The discussion below describes embodiments of systems and
methods to manage the position of diffuser vanes in a compressor
device, e.g., a centrifugal compressor. These embodiments offer a
robust and automated approach to tune operation of the compressor
device. In one aspect, these embodiments use feedback from an
actuator that couples with the diffuser vanes. The feedback can
embody, for example, an input (e.g., a digital signal, an analog
signal, etc.) that describes an operating characteristics of the
actuator. The embodiments can use this operating characteristic to
instruct the actuator to move and, in turn, manipulate the position
of the diffuser vanes, thereby reducing power consumption of the
compressor device.
[0016] Uses of the operating characteristic for the actuator can
help to achieve and maintain peak efficiency within the entire
operating envelope of the compressor device. As noted above,
movement of the actuator can modify the orientation of the diffuser
vanes, e.g., relative to the flow of a working fluid in the
compressor device. The operating characteristics may, for example,
reflect the input power (or other measure) that the actuator
requires to perform this movement and/or to maintain the diffuser
vane in a specified position relative to the flow of the working
fluid. During operation, the input power may vary; typically in
response to the change in the orientation of the diffuser vane
relative to the flow of the working fluid. To achieve optimal
performance of the compressor device, the diffuser vanes may assume
a position in which the pressure of the working fluid balances
about the surfaces of the diffuser vanes. In this position, the
input power may have its lowest and/or smallest value, e.g., thus
reflecting that the balancing of pressure of the working fluid and
that the compressor devices is operating at peak (or near-peak)
efficiency.
[0017] FIGS. 1 and 2 depict an example of a compressor device 100
that is configured to achieve optimal performance. In FIG. 1, the
compressor device 100 has an inlet 102 and a volute 104 that forms
an outlet 106. A drive unit 108 couples to an impeller 110. As best
shown in FIG. 2, the compressor device 100 includes a diffuser
assembly 112 with a plurality of diffuser vanes 114. The volute 104
forms an interior diffuser cavity that surrounds the diffuser vanes
114. The diffuser assembly 112 also includes an actuator 116, which
couples to the diffuser vanes 114 to change the position of the
diffuser vanes 114 as set forth herein.
[0018] During operation, the drive unit 108 rotates the impeller
110 to draw a working fluid (e.g., air) into the inlet 102. The
impeller 110 compresses the working fluid. The compressed working
fluid flows into the diffuser assembly 112, past the diffuser vanes
114, and through the remaining portion of the volute 104. In one
embodiment, the compressor device 100 couples with industrial
piping at the outlet 106 to expel the working fluid under pressure
and/or with certain designated flow parameters as desired. For
example, the compressor device 100 finds use in a variety of
settings and industries including automotive industries,
electronics industries, aerospace industries, oil and gas
industries, power generation industries, petrochemical industries,
and the like.
[0019] Examples of the actuator 116 can include linear actuators
and like devices that create motion in a linear or straight-line.
However, this disclosure does contemplate configurations of the
diffuser assembly 112 that can utilize devices that create
non-linear motion (e.g., rotary motion). One or more of the devices
used for the actuator 116 may generate movement in response to
electrical inputs (e.g., by way of an electric motor that drives a
lead screw) as well as in response to a pneumatic input that can
translate a piston/cylinder and/or like elements found in, for
example, a pneumatic cylinder.
[0020] FIG. 3 illustrates a schematic diagram of a system 118 for
controlling operation of the compressor device 100. The system 118
includes a controller 120 and a parameter sensor 122. The
controller 120 communicates with the drive unit 108 to control
rotation of the impeller 110. The controller 120 can also
communicate with the diffuser assembly (e.g., diffuser assembly 112
of FIG. 2) by communicating with the actuator 116. This features
can instruct operation of the actuator 116 to cause the diffuser
vanes 114 to change position, e.g., from a first position to a
second position. In one embodiment, the controller 120 (or one or
more other devices in the system 118) can communicate via a network
124 with a peripheral device 126 (e.g., a display, a computer,
smartphone, laptop, tablet, etc.) and/or an external server
128.
[0021] As also shown in FIG. 3, the system 118 includes a feedback
loop 130 that couples the controller 120 with the actuator 116. The
feedback loop 130 can conduct a signal 132 (also "an input 132")
(e.g., a digital signal, an analog signal, etc.) between the
actuator 116 and the controller 120. Examples of the signal 132 can
include data that reflects an operating characteristic for the
actuator 116. This operating characteristic can identify one or
more of input power, power consumption, current draw, voltage,
position, pneumatic pressure, as well as other conditions of the
actuator 116 during operation of the compressor device 100.
[0022] The controller 120 can use this data to manage the position
of the diffuser vane 114 in order to reduce power consumption
and/or to optimize the operating efficiency of the compressor
device 100. In one implementation, the controller 120 can instruct
the actuator 116 to operate until the operating characteristic
reaches a minimum value, e.g., which may reflect conditions in
which the input power the actuator 116 utilizes is at a minimum to
maintain the position of the diffuser vanes 114. This value may
indicate, for example, that the diffuser vane 114 is in position to
properly align leading edge and the trailing edge of the diffuser
vane 114 with the flow of the working fluid. As noted above, this
position can balance the pressure of the working fluid across the
surfaces of the diffuser vane 114. The balance in the pressure can
reduce the input power the actuator 116 needs to engage maintain
the position of the diffuser vane 114.
[0023] Examples of the controller 120 include computers and
computing devices with processors and memory that can store and
execute certain executable instructions, software programs, and the
like. The controller 120 can be a separate unit, e.g., part of a
control unit that operates the compressor device 100 and other
equipment. In other examples, the controller 120 integrates with
the compressor device 100, e.g., as part of the hardware and/or
software that operates the drive unit 108 and/or the actuator 116.
In still other examples, the controller 120 can be located remote
from the compressor device 100, e.g., in a separate location. The
controller 120 can issue commands and instructions using wireless
and wired communication, e.g., via the network 124.
[0024] The parameter sensor 122 monitors one or more operating
parameters of the compressor device 100. Examples of these
operating parameters include flow parameters (e.g., flow rate, flow
velocity, static pressure, head pressure, etc.) and mechanical
parameters (e.g., input power, current, voltage, torque, etc.),
among others. The parameter sensor 122 can comprise one or more
sensor devices that are sensitive to the operating parameters.
These sensor devices can embody flow meters, pressure transducers,
accelerometers, and like components. Such devices generate signals
(also, "inputs")(e.g., digital signals, analog signals, etc.),
which include data that reflects a measured value for the
corresponding operating parameter that the device is configured to
measure.
[0025] The parameter sensor 122 may also couple with a shaft or
other mechanism that transfers energy from the drive unit 108 to
the impeller 110. When used in this manner, the parameter sensor
122 can measure several operating parameters (e.g., torque, angular
velocity, etc.) that define the operation of the drive unit 108
and/or the compressor device 102 in general. Other positions for
the parameter sensor 122 include proximate the interior of the
volute 104, proximate the outlet 106, proximate the diffuser
assembly (e.g., diffuser assembly 112 of FIG. 2) as well as other
positions to measure flow parameters as the working fluid moves
through the compressor device 100. Moreover, the compressor device
100 may include circuitry to operate the drive unit 108 that
includes certain configurations of elements (e.g., capacitors,
resistors, transistors, etc.) to monitor inputs to the drive unit
108, e.g., current, voltage, power, etc.
[0026] Embodiments of the system 118 can implement sensor devices
(e.g., parameter sensor 122) in various combinations to monitor and
measure different operating parameters throughout the compressor
device 100. For example, the system 118 may deploy a flow meter
upstream of the diffuser vanes 114, a pressure sensor proximate the
outlet 106 (FIGS. 1 and 2), and/or circuitry to monitor the amount
of power the actuator 116 and/or the drive unit 108 uses during
operation of the compressor device 100. The sensor devices provide
signals to the controller 120. These signals transmit and/or
include data and information that reflects the operation of the
compressor device 100. The controller 120 can process the signals
from the sensor devices to generate the outputs. These outputs can
include data that reflects instructions for operation of one or
more components that can configure the compressor device 100. As
set forth more below, the outputs can include data that reflects
instructions to change the position of the diffuser vanes 114,
e.g., to instruct operation of the actuator 116 to change the
orientation and/or position of one or more of the diffuser vanes
114. These instructions may, for example, cause the actuator 116 to
move, which, in turn, moves (e.g., rotates) the diffuser vanes 114
through an angular offset from the first position to the second
position.
[0027] FIG. 4 illustrates a flow diagram of an exemplary embodiment
of a method 200 to operate a compressor device (e.g., compressor
device 100 of FIGS. 1, 2, and 3). The method 200 includes, at step
202, receiving a first signal (also, "first input") including data
that reflects a first value for an operating characteristic of an
actuator that couples with the diffuser vane in a first position
and, at step 204, receiving a second signal (also, "second input")
including data that reflects a second value for the operating
parameter of the actuator with the diffuser vane in a second
position. The method 200 also includes, at step 206, comparing the
first value and the second value. The method 200 further includes,
at step 208, selecting an increment by which to move the diffuser
vanes and, at step 210, generating an output that includes data to
instruct the actuator to move the diffuser vane from the second
position by the increment.
[0028] Collectively, one or more of the steps of the method 200 can
be coded as one or more executable instructions (e.g., hardware,
firmware, software, software programs, etc.). These executable
instructions can be part of a computer-implemented method and/or
program, which can be executed by a processor and/or processing
device. Examples of the controller 120 (FIG. 3) can execute these
executable instruction to generate certain outputs, e.g., a signal
that encodes instructions to change the position of the diffuser
vanes 114 (FIGS. 1, 2, and 3), a signal that encodes instructions
to change operation of the drive unit 108 (FIGS. 1, 2, and 3),
etc.
[0029] The steps for receiving a first signal (e.g., at step 202)
and a second signal (e.g., a step 204) occur at different positions
of the diffuser vanes 114 (FIGS. 2 and 3) to capture potential
changes in the operating characteristic of the actuator 116 (FIGS.
1, 2, and 3). To illustrate, FIG. 5 shows an example of a diffuser
vane 300 in a first position 302 and a second position, identified
by phantom lines and the numeral 304. In one embodiment, the
diffuser vane 300 changes between the first position 302 and the
second position 304 in response to operation of the actuator 116
(FIGS. 1, 2, and 3).
[0030] The diffuser vane 300 has a vane body 306 with a leading
edge 308 and a trailing edge 310. The diffuser vane 300 rotates
about a rotation axis 312 to permit changes in the position of the
trailing edge 310 relative to, in one example, the leading edge
308. This disclosure also contemplates construction of the diffuser
vane 300 that would allow both the leading edge 308 and the
trailing edge 310 to move about the rotation axis 312. For example,
the rotation axis 312 can be positioned at various locations along
the vane body 306, e.g., in locations spaced apart from the leading
edge 308 and the trailing edge 310 along a chord length. The chord
length measures the straight-line distance between the leading edge
308 and the trailing edge 310.
[0031] With respect to the configuration of the diffuser vane 300
in FIG. 5, rotation about the leading edge 308 is advantageous to
accommodate the direction of the flow F, which can change
orientation e.g., from a first flow direction F1 to a second flow
direction F2. To this end, despite the relatively large angular
displacement of the trailing edge 310 that occurs, the leading edge
308 is secured on the rotation axis 312 to limit changes to the
position of the leading edge 308 as the trailing edge 310 moves
between the first position 302 and the second position 304. This
feature maintains the orientation of the leading edge 308 with the
second flow F2 to reduce the likelihood of flow separation, while
providing adequate adjustment of the trailing edge 310 to dictate
changes in the performance, e.g., of the compressor device 100
(FIGS. 1, 2, and 3).
[0032] Communication of the first signal and the second signal can
occur by way of wireless and/or wired communication protocols. In
one implementation, systems can utilize these protocols to convey
data to the controller 120 (FIG. 3) from the actuator 116 (FIGS. 1,
2, and 3) by way of the feedback loop 130 (FIG. 3) and/or between
one or more of the parameter sensors 122 (FIG. 3) and the
controller 120 (FIG. 3). The signal encodes information about the
operating characteristics for the actuator 116 (FIGS. 1, 2, and 3).
This data can include values (also "measured values") that may
reflect a determinant values (e.g., voltage level, current level,
power, pressure, etc.) that defines one or more operating
characteristics for the actuator 116 (FIGS. 1, 2, and 3) that is
the subject of measurement. In one embodiment, the method 200 can
include steps for receiving a plurality of signals from different
sensor devices and for selecting one or more of the signals based
on, for example, the type of information and data included in the
signals. These features of the method 200 can permit the selection
of particular information, e.g., flow rate of incoming working
fluid upstream of the impeller 110 (FIG. 1) and/or the diffuser
vanes 114 (FIGS. 1, 2, and 3), and/or combinations of information,
e.g., flow rate of incoming working fluid upstream of the impeller
110 (FIG. 1) and/or the diffuser vanes 114 (FIGS. 1, 2, and 3),
pressure at the outlet 106 (FIGS. 1 and 2), and input power of the
actuator 116 (FIGS. 1, 2, and 3). These selections may be part of a
user interface (e.g., a graphical user interface) that displays on
one or more of the peripheral devices 126 (FIG. 3) or on other
display equipment associated with the compressor device 100 (FIGS.
1, 2, and 3) and/or the system 118 (FIG. 3).
[0033] The steps for comparing the first value and the second value
(e.g., a step 206) identifies the change or variation in the
operating characteristic of the actuator 116 (FIGS. 1, 2, and 3)
that corresponds with the change in position of the diffuser vane
300. These changes can, for example, increase and/or decrease the
operating characteristic of the actuator 116. For purpose of one
example, this comparison captures the relative change in input
power (or power consumption) of the actuator 116 (FIGS. 1, 2, and
3) that is required to move the diffuser vane 300 from the first
position 302 to the second position 304. In another example, the
comparison can identify the input power of the actuator 116 (FIGS.
1, 2, and 3) to maintain the position of diffuser vane 300.
[0034] The steps for selecting an increment (e.g., at step 208)
provides an incremental change in the position of the diffuser
vanes 300. This incremental change moves the diffuser vanes 300 to
another position, which in turn can change the value of the
operating characteristic of the actuator 116 (FIGS. 1, 2, and 3).
Examples of the incremental change can define both the amount of
movement that will occur in the diffuser vane 300 as well as the
direction of movement. FIG. 6, for example, illustrates the
diffuser vane 300 in a third position 314, which represents the
position of the diffuser vane 300 offset from the second position
302 by an increment 316. As shown in the example of FIG. 6, the
increment 316 defines several positional characteristics (e.g., an
angular offset 318 and a direction 320) that determine the extent
to which the position of the diffuser vane 300 changes relative to
the second position 304. In one embodiment, the method 200 can
include steps for comparing the relative values of the first value
and the second value to assign the positional characteristics. For
example, if the second value is less than the first value, then the
method 200 can include steps for assigning the increment 316 a
first set of positional characteristics that comprise a first
direction and a first angular offset. On the other hand, if the
second value is less than the first value, then the method 200 can
include steps for assigning the increment 316 a second set of
positional characteristics that comprise a second direction and a
second angular offset. In one example, the first direction is
different from the second direction (e.g., with respect of FIG. 6,
the first direction is clockwise and the second direction is
counter clockwise).
[0035] The amount of the angular offset can vary, both between the
first angular offset and the second angular offset as well as based
on the first value and the second value for the operating
characteristic. For example, embodiments of the method 200 may
include steps for calculating a variation value, which can have a
value equal to the mathematical difference between the first value
and the second value, and a step for comparing the variation value
to a threshold criteria that can define the nominal values for the
positional characteristics. In one example, if the variation value
satisfies the threshold criteria, then the method 200 may include
steps for assigning values to the increment 316. These values may
decrease as the variation value decreases, e.g., as the operating
characteristic of the actuator 116 (FIGS. 1, 2, and 3) converges to
an optimal value (e.g., a minimum current level that indicates of
the optimal position for the diffuser vanes).
[0036] The steps for generating an output (e.g., at step 210) can
cause the actuator 116 (FIGS. 1, 2, and 3) to move (also, actuator)
to move the diffuser vane 300 between the second position 304 and
the third position 314. The output can comprise any signal (e.g.,
analog and/or digital) that can include data that reflect
instructions to operate a device. In the examples herein, the
output can cause the actuator 116 (FIGS. 1, 2, and 3) to move
between a first actuated position and a second actuated position,
which can facilitate movement either directly and/or indirectly of
the diffuser vanes (e.g., diffuser vanes 114 of FIGS. 2 and 3
and/or diffuser vane 300 of FIGS. 5 and 6) among and between one or
more of the first position 302, the second position 304, and the
third position 314.
[0037] In view of the foregoing discussion of the method 200, this
disclosure contemplates embodiments in which the method 200
embodies an iterative and/or multi-operational technique to focus
and optimize operation, e.g., of the compressor device 100 (FIGS.
1, 2, and 3). To this end, the method 200 may include one or more
steps for resetting and or initializing one or more values for the
operating characteristic for the actuator 116 (FIGS. 1, 2, and 3)
and the positional characteristics. This feature prepares the
methodology to accept additional data and/or to operate in a manner
that promotes incremental changes in the position of the diffuser
vanes (e.g., diffuser vanes 114 of FIGS. 1, 2, and 3 and diffuser
vane 300 of FIGS. 5 and 6). For example, in one embodiment, on a
second "pass" through the method 200, the first value from the
operating parameter may be assigned the second value and, in turn,
the second value may comprise a new value that identifies the
operating value that occurs after the diffuser vane changes from
the second position to the third position. In this way, the method
200 can compare at least one previous value to a new value for
purposes of iterating the methodology to an optimum solution. For
purposes of such an example, it may be unnecessary to receive
and/or decode both the first signal (e.g., at step 202), but rather
supplement the steps of the method 200 with one or more steps for
assigning the first value with the second value, initializing the
second value, and continuing on to receiving the second signal
(e.g., at step 204).
[0038] FIG. 7 depicts a schematic diagram that presents, at a high
level, a wiring schematic for a controller 400 that can process
data (e.g., signals) to generate an output that instructs operation
of a compressor device (e.g., compressor device 100 of FIGS. 1, 2,
and 3). The controller 400 can be incorporated as part of a
compressor device to provide an integrated and effective
stand-alone system. In other alternatives, the controller 400 can
remain separate and/or as part of a control system, which can also
monitor various operations of the compressor device as well as the
systems coupled thereto.
[0039] In one embodiment, the controller 400 includes a processor
402, memory 404, and control circuitry 406. Busses 408 couple the
components of the controller 400 together to permit the exchange of
signals, data, and information from one component of the controller
400 to another. In one example, the control circuitry 406 includes
sensor driver circuitry 410 which couples with a parameter sensor
412 (e.g., parameter sensor 122 of FIG. 3) and motor drive
circuitry 414 that couples with a drive unit 416 (e.g., e.g. drive
unit 108 of FIGS. 1, 2, and 3). The control circuitry 406 also
includes an actuator drive circuitry 418, which couples with an
actuator 420 (e.g., actuators 116 of FIGS. 1, 2, and 3), and a
radio circuitry 422 that couples to a radio 424, e.g., a device
that operates in accordance with one or more of the wireless and/or
wired protocols for sending and/or receiving electronic messages to
and from a peripheral device 426 (e.g., a smartphone). As also
shown in FIG. 7, memory 404 can include one or more software
programs 428 in the form of software and/or firmware, each of which
can comprise one or more executable instructions configured to be
executed by the processor 402.
[0040] This configuration of components can dictate operation of
the controller 400 to analyze data, e.g., information included in
the signals from parameter sensor 412, the drive unit 414, and the
actuator 420 to identify appropriate changes to the diffuser vanes
and/or other changes to other operating properties (e.g., motor
speed) of the compressor device. For example, the controller 400
can provide signals (or inputs or outputs) to speed up and slow
down the drive unit 416, to instruct the actuator 420 to move to
change the diffuser vanes from the first position to the second
position, and/or actuate other devices that change the operation of
the compressor device (e.g., compressor device 100 of FIGS. 1, 2,
and 3).
[0041] The controller 400 and its constructive components can
communicate amongst themselves and/or with other circuits (and/or
devices), which execute high-level logic functions, algorithms, as
well as executable instructions (e.g., firmware instructions,
software instructions, software programs, etc.). Exemplary circuits
of this type include discrete elements such as resistors,
transistors, diodes, switches, and capacitors. Examples of the
processor 402 include microprocessors and other logic devices such
as field programmable gate arrays ("FPGAs") and application
specific integrated circuits ("ASICs"). Although all of the
discrete elements, circuits, and devices function individually in a
manner that is generally understood by those artisans that have
ordinary skill in the electrical arts, it is their combination and
integration into functional electrical groups and circuits that
generally provide for the concepts that are disclosed and described
herein.
[0042] The structure of the components in the controller 400 can
permit certain determinations as to selected configuration and
desired operating characteristics that an end user convey via the
graphical user interface or that are retrieved or need to be
retrieved by the device. For example, the electrical circuits of
the controller 400 can physically manifest theoretical analysis and
logical operations and/or can replicate in physical form an
algorithm, a comparative analysis, and/or a decisional logic tree,
each of which operates to assign the output and/or a value to the
output that correctly reflects one or more of the nature, content,
and origin of the changes that occur and that are reflected by the
inputs to the controller 400 as provided by the corresponding
control circuitry, e.g., in the control circuitry 406.
[0043] In one embodiment, the processor 402 is a central processing
unit (CPU) such as an ASIC and/or an FPGA that is configured to
instruct and/or control operation one or more devices. This
processor can also include state machine circuitry or other
suitable components capable of controlling operation of the
components as described herein. The memory 404 includes volatile
and non-volatile memory and can store executable instructions in
the form of and/or including software (or firmware) instructions
and configuration settings. Each of the control circuitry 406 can
embody stand-alone devices such as solid-state devices. Examples of
these devices can mount to substrates such as printed-circuit
boards and semiconductors, which can accommodate various components
including the processor 402, the memory 404, and other related
circuitry to facilitate operation of the controller 400. In other
embodiments, the memory 404 and processor 402 are remote from one
another, e.g., the memory 404 is part of a server, computer, and/or
computing device, as well as part of a cloud computing network. In
either this remote configuration, or local configuration as shown
in FIG. 7, the processor 402 can have access to executable
instruction that are stored on memory and configured to be executed
by the processor 404.
[0044] Moreover, although FIG. 7 shows the processor 402, the
memory 404, and the components of the control circuitry 406 as
discrete circuitry and combinations of discrete components, this
need not be the case. For example, one or more of these components
can comprise a single integrated circuit (IC) or other component.
As another example, the processor 402 can include internal program
memory such as RAM and/or ROM. Similarly, any one or more of
functions of these components can be distributed across additional
components (e.g., multiple processors or other components).
[0045] Further, as will be appreciated by one skilled in the art
and contemplated herein, aspects of the present disclosure may be
embodied as a system, method, computer-implemented method, and/or
computer program product. Accordingly, aspects of the present
disclosure may take the form of an entirely hardware embodiment, an
entirely software embodiment (including one or more of firmware,
resident software, micro-code, etc.) or an embodiment combining
software and hardware aspects that may all generally be referred to
herein as a "circuit," "module" or "system." Furthermore, aspects
of the present disclosure may take the form of a computer program
product embodied in one or more computer readable medium(s) having
computer readable program code and/or executable instructions
embodied thereon.
[0046] Any combination of one or more computer readable medium(s)
may be utilized. The computer readable medium may be a
non-transitory computer readable signal medium or a non-transitory
computer readable storage medium. Examples of a computer readable
storage medium include an electronic, magnetic, electromagnetic,
and/or semiconductor system, apparatus, or device, or any suitable
combination of the foregoing. More specific examples (a
non-exhaustive list) of the computer readable storage medium would
include the following: an electrical connection having one or more
wires, a portable computer diskette, a hard disk, a random access
memory (RAM), a read-only memory (ROM), an erasable programmable
read-only memory (EPROM or Flash memory), an optical fiber, a
portable compact disc read-only memory (CD-ROM), an optical storage
device, a magnetic storage device, or any suitable combination of
the foregoing. In the context of this document, a computer readable
storage medium may be any tangible medium that can contain, or
store a program for use by or in connection with an instruction
execution system, apparatus, or device.
[0047] Program code embodied on a computer readable medium may be
transmitted using any appropriate medium, including but not limited
to wireless, wireline, optical fiber cable, RF, etc., or any
suitable combination of the foregoing. This program code may be
written in any combination of one or more programming languages,
including an object oriented programming language and conventional
procedural programming languages. The program code may execute
entirely on the user's computer, partly on the user's computer, as
a stand-alone software package, partly on the user's computer and
partly on a remote computer or entirely on the remote computer or
server. In the latter scenario, the remote computer may be
connected to the user's computer through any type of network,
including a local area network (LAN) or a wide area network (WAN),
or the connection may be made to an external computer (for example,
through the Internet using an Internet Service Provider).
[0048] The executable or computer program instructions may be
provided to a processor of a general purpose computer, special
purpose computer, or other programmable data processing apparatus
to produce a machine, such that the instructions, which execute via
the processor of the computer or other programmable data processing
apparatus. The computer program instructions may also be stored in
and/or on a computer readable medium that can direct a computer,
other programmable data processing apparatus, or other devices to
function in a particular manner.
[0049] Accordingly, a technical effect of embodiments of the
systems and methods disclosed herein is to monitor the operation of
the actuator to position the diffuser vanes in locations at which,
in one example, the compressor device consumes the least amount of
power.
[0050] As used herein, an element or function recited in the
singular and proceeded with the word "a" or "an" should be
understood as not excluding plural said elements or functions,
unless such exclusion is explicitly recited. Furthermore,
references to "one embodiment" of the claimed invention should not
be interpreted as excluding the existence of additional embodiments
that also incorporate the recited features.
[0051] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
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