U.S. patent application number 13/908788 was filed with the patent office on 2014-12-04 for electronic expansion valve.
The applicant listed for this patent is Trane International Inc.. Invention is credited to Thomas Eugene Burklin, John Randolph Cuellar, Humberto Ramon Maldonado, Audy Porter.
Application Number | 20140353391 13/908788 |
Document ID | / |
Family ID | 51983986 |
Filed Date | 2014-12-04 |
United States Patent
Application |
20140353391 |
Kind Code |
A1 |
Burklin; Thomas Eugene ; et
al. |
December 4, 2014 |
Electronic Expansion Valve
Abstract
An electronic expansion valve for an HVAC system and method of
operating the same is provided, wherein the EEV comprises a
longitudinal displacement axis, an obturator, a rotor comprising a
magnet, a first sensor disposed along the longitudinal displacement
axis at a first longitudinal location and configured to output a
first voltage, and a second sensor disposed along the longitudinal
displacement axis at a second longitudinal location and configured
to output a second voltage, wherein the first longitudinal location
is longitudinally displaced from the second longitudinal location
along the longitudinal displacement axis, and wherein the position,
direction of movement, linear speed, angular speed, and angular
displacement of an obturator may be determined as a result of the
first voltage output from the first sensor and second voltage
output from the second sensor.
Inventors: |
Burklin; Thomas Eugene;
(Tyler, TX) ; Maldonado; Humberto Ramon;
(Whitehouse, TX) ; Cuellar; John Randolph;
(Mineola, TX) ; Porter; Audy; (Frankston,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Trane International Inc. |
Piscataway |
NJ |
US |
|
|
Family ID: |
51983986 |
Appl. No.: |
13/908788 |
Filed: |
June 3, 2013 |
Current U.S.
Class: |
236/92B |
Current CPC
Class: |
F25B 2341/0653 20130101;
Y02B 30/70 20130101; F25B 41/062 20130101; Y02B 30/72 20130101 |
Class at
Publication: |
236/92.B |
International
Class: |
F25B 41/04 20060101
F25B041/04 |
Claims
1. An electronic expansion valve, comprising: a longitudinal
displacement axis; a rotor comprising a magnet; a first sensor
disposed along the longitudinal displacement axis at a first
longitudinal location; and a second sensor disposed along the
longitudinal displacement axis at a second longitudinal location;
wherein the first longitudinal location is longitudinally offset
from the second longitudinal location along the longitudinal
displacement axis.
2. The electronic expansion valve of claim 1, wherein at least one
of the first sensor and the second sensor comprises a Hall Effect
sensor.
3. The electronic expansion valve of claim 1, wherein the first
sensor is configured to sense the proximity of the rotor magnet at
the first longitudinal location and the second sensor is configured
to sense the proximity of the rotor magnet at the second
longitudinal location.
4. The electronic expansion valve of claim 1, further comprising an
obturator, wherein the first sensor is configured to sense the
proximity of the rotor magnet at the first longitudinal location
and output a first voltage and the second sensor is configured to
sense the proximity of the rotor magnet at the second longitudinal
location and output a second voltage, wherein the first voltage and
the second voltage are used to determine at least one of the
following: position of the obturator along the longitudinal
displacement axis, direction of movement of the obturator along the
longitudinal displacement axis, linear speed of the obturator along
the longitudinal displacement axis, angular displacement of the
obturator about the longitudinal displacement axis, and rotational
speed of the obturator about the longitudinal displacement
axis.
5. The electronic expansion valve of claim 1, further comprising a
plurality of triggers.
6. The electronic expansion valve of claim 5, wherein the first
sensor and the second sensor are configured to detect the plurality
of triggers.
7. The electronic expansion valve of claim 5, wherein the triggers
are carried by the rotor magnet.
8. The electronic expansion valve of claim 5, wherein the triggers
collectively comprise the rotor magnet.
9. The electronic expansion valve of claim 5, further comprising a
rotor extension, wherein the triggers are carried by the rotor
extension.
10. The electronic expansion valve of claim 5, wherein the triggers
are carried by the rotor.
11. The electronic expansion valve of claim 5, wherein the triggers
are carried by the rotor and configured in a helical pattern that
is coincidental with a thread pitch of the rotor along the
longitudinal displacement axis of travel of the rotor.
12. A heating, ventilation, and/or air conditioning (HVAC) system,
comprising: an electronic expansion valve comprising a longitudinal
displacement axis, a rotor comprising a magnet, a first sensor
disposed along the longitudinal displacement axis at a first
longitudinal location, and a second sensor disposed along the
longitudinal displacement axis at a second longitudinal location,
wherein the first longitudinal location is longitudinally offset
from the second longitudinal location along the longitudinal
displacement axis; and an electronic expansion valve
controller.
13. The HVAC system of claim 12, wherein at least one of the first
sensor and the second sensor comprise a Hall Effect Sensor.
14. The HVAC system of claim 12, wherein the first sensor is
configured to output a first voltage as a result of the a sensed
proximity of the magnet to the first sensor, and the second sensor
is configured to output a second voltage as a result of the sensed
proximity of the magnet to the second sensor.
15. The HVAC system of claim 12, further comprising an obturator,
wherein the first sensor is configured to output a first voltage as
a result of the a sensed proximity of the magnet to the first
sensor and the second sensor is configured to output a second
voltage as a result of the sensed proximity of the magnet to the
second sensor to determine at least one of the following: position
of the obturator along the longitudinal displacement axis,
direction of movement of the obturator along the longitudinal
displacement axis, linear speed of the obturator along the
longitudinal displacement axis, angular displacement of the
obturator about the longitudinal displacement axis, and rotational
speed of the obturator about the longitudinal displacement
axis.
16. The HVAC system of claim 14, wherein the first voltage and the
second voltage are received by the electronic expansion valve
controller to determine at least one of the following: position of
the obturator along the longitudinal displacement axis, direction
of movement of the obturator along the longitudinal displacement
axis, linear speed of the obturator along the longitudinal
displacement axis, angular displacement of the obturator about the
longitudinal displacement axis, and rotational speed of the
obturator about the longitudinal displacement axis.
17. A method of operating an electronic expansion valve,
comprising: providing an electronic expansion valve comprising a
longitudinal displacement axis, a rotor comprising a magnet, an
obturator, a first sensor disposed along the longitudinal
displacement axis at a first longitudinal location, and a second
sensor disposed along the longitudinal displacement axis at a
second longitudinal location, wherein the first longitudinal
location is longitudinally offset from the second longitudinal
location along the longitudinal displacement axis; sensing the
relative position of the obturator within the electronic expansion
valve by the first sensor at the first longitudinal location and
the second sensor at the second longitudinal location; outputting a
first voltage from the first sensor to an electronic expansion
valve controller; and outputting a second voltage from the second
sensor to an electronic expansion valve controller.
18. The method of claim 17, further comprising: determining, as a
function of the first voltage and the second voltage, at least one
of a position of the obturator along the longitudinal displacement
axis, a direction of movement of the obturator along the
longitudinal displacement axis, a linear speed of the obturator
along the longitudinal displacement axis, an angular displacement
of the obturator about the longitudinal displacement axis, and a
rotational speed of the obturator about the longitudinal
displacement axis.
19. The method of claim 17, wherein at least one of the first
sensor and the second sensor comprises a Hall Effect Sensor.
20. The method of claim 17, wherein the electronic expansion valve
is a component of a heating, ventilation, and/or air conditioning
system.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND
[0004] Some heating, ventilation, and/or air conditioning (HVAC)
systems may comprise an electronic expansion valve (EEV) that
regulates a flow of refrigerant entering a heat exchanger. The EEV
may generally comprise a stepper motor which receives signals from
an electronic controller to control the position of an obturator of
an EEV. In some instances, however, the EEV may not be correctly
calibrated.
SUMMARY
[0005] In some embodiments of the disclosure, an electronic
expansion valve comprising a longitudinal displacement axis, a
rotor comprising a magnet, a first sensor disposed along the
longitudinal displacement axis at a first longitudinal location,
and a second sensor disposed along the longitudinal displacement
axis at a second longitudinal location, wherein the first
longitudinal location is longitudinally offset from the second
longitudinal location along the longitudinal displacement axis is
disclosed.
[0006] In other embodiments of the disclosure, a heating,
ventilation, and air conditioning system comprising an electronic
expansion valve comprising a longitudinal displacement axis, a
rotor comprising a magnet, a first sensor disposed along the
longitudinal displacement axis at a first longitudinal location,
and a second sensor disposed along the longitudinal displacement
axis at a second longitudinal location, wherein the first
longitudinal location is longitudinally offset from the second
longitudinal location along the longitudinal displacement axis, and
an electronic expansion valve controller is disclosed.
[0007] In yet other embodiments of the disclosure, a method of
operating an electronic expansion valve comprising: providing an
electronic expansion valve comprising a longitudinal displacement
axis, a rotor comprising a magnet, an obturator, a first sensor
disposed along the longitudinal displacement axis at a first
longitudinal location, and a second sensor disposed along the
longitudinal displacement axis at a second longitudinal location,
wherein the first longitudinal location is longitudinally offset
from the second longitudinal location along the longitudinal
displacement axis, sensing the position of the obturator within the
electronic expansion valve by the first sensor at the first
longitudinal location and the second sensor at the second
longitudinal location, outputting a first voltage from the first
sensor to an electronic expansion valve controller, and outputting
a second voltage from the second sensor to an electronic expansion
valve controller is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present disclosure
and the advantages thereof, reference is now made to the following
brief description, taken in connection with the accompanying
drawings and detailed description:
[0009] FIG. 1 is simplified schematic diagram of an HVAC system
according to an embodiment of the disclosure;
[0010] FIG. 2 is a simplified schematic diagram of the air
circulation paths of the HVAC system of FIG. 1;
[0011] FIG. 3 is a cutaway view of an electronic expansion valve at
a metering position according to an embodiment of the
disclosure;
[0012] FIG. 4 is a cutaway view of an electronic expansion valve at
a fully open position according to an embodiment of the
disclosure;
[0013] FIG. 5 is a cutaway view of an electronic expansion valve at
a fully closed position according to an embodiment of the
disclosure;
[0014] FIG. 6 is a cutaway view of an electronic expansion valve at
a fully open position according to an embodiment of the
disclosure;
[0015] FIG. 7 is a cutaway view of an electronic expansion valve at
a fully open position according to an embodiment of the
disclosure;
[0016] FIG. 8 is a cutaway view of an electronic expansion valve at
a fully open position according to an embodiment of the disclosure;
and
[0017] FIG. 9 is a partial cutaway view of an electronic expansion
valve at a fully open position according to an embodiment of the
disclosure.
DETAILED DESCRIPTION
[0018] In some instances, it may be desirable to provide an
electronic expansion valve (EEV) that is capable of more accurate
control and monitoring. For example, where an EEV is not correctly
calibrated, it may be desirable to utilize an EEV that comprises
internal Hall Effect sensors to more accurately monitor and control
the position of the obturator of an EEV. In other instances, it may
also be desirable to instantaneously determine and verify the
position and direction of movement of the obturator of an EEV. In
some embodiments of the disclosure, systems and methods are
disclosed that comprise providing an EEV that comprises a plurality
of Hall Effect sensors that are longitudinally displaced along an
axis of movement of the EEV and configured to detect the position
and movement of the obturator of an EEV.
[0019] Referring now to FIG. 1, a simplified schematic diagram of
an HVAC system 100 according to an embodiment of this disclosure is
shown. HVAC system 100 comprises an indoor unit 102, an outdoor
unit 104, and a system controller 106. In some embodiments, the
system controller 106 may operate to control operation of the
indoor unit 102 and/or the outdoor unit 104. As shown, the HVAC
system 100 is a so-called heat pump system that may be selectively
operated to implement one or more substantially closed
thermodynamic refrigeration cycles to provide a cooling
functionality and/or a heating functionality.
[0020] Indoor unit 102 comprises an indoor heat exchanger 108, an
indoor fan 110, and an electronic expansion valve (EEV) 112. Indoor
heat exchanger 108 is a plate fin heat exchanger configured to
allow heat exchange between refrigerant carried within internal
tubing of the indoor heat exchanger 108 and fluids that contact the
indoor heat exchanger 108 but that are kept segregated from the
refrigerant. In other embodiments, indoor heat exchanger 108 may
comprise a spine fin heat exchanger, a microchannel heat exchanger,
or any other suitable type of heat exchanger.
[0021] The indoor fan 110 is a centrifugal blower comprising a
blower housing, a blower impeller at least partially disposed
within the blower housing, and a blower motor configured to
selectively rotate the blower impeller. In other embodiments, the
indoor fan 110 may comprise a mixed-flow fan and/or any other
suitable type of fan. The indoor fan 110 is configured as a
modulating and/or variable speed fan capable of being operated at
many speeds over one or more ranges of speeds. In other
embodiments, the indoor fan 110 may be configured as a multiple
speed fan capable of being operated at a plurality of operating
speeds by selectively electrically powering different ones of
multiple electromagnetic windings of a motor of the indoor fan 110.
In yet other embodiments, the indoor fan 110 may be a single speed
fan.
[0022] The electronic expansion valve (EEV) 112 is an
electronically controlled motor driven EEV. In alternative
embodiments, the HVAC system 100 may comprise a thermostatic
expansion valve, a capillary tube assembly, and/or any other
suitable metering device other than an EEV. The EEV 112 may
comprise and/or be associated with a refrigerant check valve and/or
refrigerant bypass for use when a direction of refrigerant flow
through the EEV 112 is such that the EEV 112 is not intended to
meter or otherwise substantially restrict flow of the refrigerant
through the EEV 112.
[0023] Outdoor unit 104 comprises an outdoor heat exchanger 114, a
compressor 116, an outdoor fan 118, an outdoor metering device 120,
and a reversing valve 122. Outdoor heat exchanger 114 is a spine
fin heat exchanger configured to allow heat exchange between
refrigerant carried within internal passages of the outdoor heat
exchanger 114 and fluids that contact the outdoor heat exchanger
114 but that are kept segregated from the refrigerant. In other
embodiments, outdoor heat exchanger 114 may comprise a plate fin
heat exchanger, a microchannel heat exchanger, or any other
suitable type of heat exchanger.
[0024] The compressor 116 is a multiple speed scroll type
compressor configured to selectively pump refrigerant at a
plurality of mass flow rates. In alternative embodiments, the
compressor 116 may comprise a modulating compressor capable of
operation over one or more speed ranges, the compressor 116 may
comprise a reciprocating type compressor, the compressor 116 may be
a single speed compressor, and/or the compressor 116 may comprise
any other suitable refrigerant compressor and/or refrigerant
pump.
[0025] The outdoor fan 118 is an axial fan comprising a fan blade
assembly and fan motor configured to selectively rotate the fan
blade assembly. In other embodiments, the outdoor fan 118 may
comprise a mixed-flow fan, a centrifugal blower, and/or any other
suitable type of fan and/or blower. The outdoor fan 118 is
configured as a modulating and/or variable speed fan capable of
being operated at many speeds over one or more ranges of speeds. In
other embodiments, the outdoor fan 118 may be configured as a
multiple speed fan capable of being operated at a plurality of
operating speeds by selectively electrically powering different
ones of multiple electromagnetic windings of a motor of the outdoor
fan 118. In yet other embodiments, the outdoor fan 118 may be a
single speed fan.
[0026] The outdoor metering device 120 is a thermostatic expansion
valve. In alternative embodiments, the outdoor metering device 120
may comprise an electronically controlled motor driven EEV similar
to EEV 112, a capillary tube assembly, and/or any other suitable
metering device. The outdoor metering device 120 may comprise
and/or be associated with a refrigerant check valve and/or
refrigerant bypass for use when a direction of refrigerant flow
through the outdoor metering device 120 is such that the outdoor
metering device 120 is not intended to meter or otherwise
substantially restrict flow of the refrigerant through the outdoor
metering device 120.
[0027] The reversing valve 122 is a so-called four-way reversing
valve. The reversing valve 122 may be selectively controlled to
alter a flow path of refrigerant in the HVAC system 100 as
described in greater detail below. The reversing valve 122 may
comprise an electrical solenoid or other device configured to
selectively move a component of the reversing valve 122 between
operational positions.
[0028] The system controller 106 may comprise a touchscreen
interface for displaying information and for receiving user inputs.
The system controller 106 may display information related to the
operation of the HVAC system 100 and may receive user inputs
related to operation of the HVAC system 100. However, the system
controller 106 may further be operable to display information and
receive user inputs tangentially and/or unrelated to operation of
the HVAC system 100. In some embodiments, the system controller 106
may comprise a temperature sensor and may further be configured to
control heating and/or cooling of zones associated with the HVAC
system 100. In some embodiments, the system controller 106 may be
configured as a thermostat for controlling supply of conditioned
air to zones associated with the HVAC system.
[0029] In some embodiments, the system controller 106 may
selectively communicate with an indoor controller 124 of the indoor
unit 102, with an outdoor controller 126 of the outdoor unit 104,
and/or with other components of the HVAC system 100. In some
embodiments, the system controller 106 may be configured for
selective bidirectional communication over a communication bus 128.
In some embodiments, portions of the communication bus 128 may
comprise a three-wire connection suitable for communicating
messages between the system controller 106 and one or more of the
HVAC system 100 components configured for interfacing with the
communication bus 128. Still further, the system controller 106 may
be configured to selectively communicate with HVAC system 100
components and/or other device 130 via a communication network 132.
In some embodiments, the communication network 132 may comprise a
telephone network and the other device 130 may comprise a
telephone. In some embodiments, the communication network 132 may
comprise the Internet and the other device 130 may comprise a
so-called smartphone and/or other Internet enabled mobile
telecommunication device.
[0030] The indoor controller 124 may be carried by the indoor unit
102 and may be configured to receive information inputs, transmit
information outputs, and otherwise communicate with the system
controller 106, the outdoor controller 126, and/or any other device
130 via the communication bus 128 and/or any other suitable medium
of communication. In some embodiments, the indoor controller 124
may be configured to communicate with an indoor personality module
134, receive information related to a speed of the indoor fan 110,
transmit a control output to an electric heat relay, transmit
information regarding an indoor fan 110 volumetric flow-rate,
communicate with and/or otherwise affect control over an air
cleaner 136, and communicate with an indoor EEV controller 138. In
some embodiments, the indoor controller 124 may be configured to
communicate with an indoor fan controller 142 and/or otherwise
affect control over operation of the indoor fan 110. In some
embodiments, the indoor personality module 134 may comprise
information related to the identification and/or operation of the
indoor unit 102 and/or a position of the outdoor metering device
120.
[0031] In some embodiments, the indoor EEV controller 138 may be
configured to receive information regarding temperatures and/or
pressures of the refrigerant in the indoor unit 102. More
specifically, the indoor EEV controller 138 may be configured to
receive information regarding temperatures and pressures of
refrigerant entering, exiting, and/or within the indoor heat
exchanger 108. Further, the indoor EEV controller 138 may be
configured to communicate with the EEV 112 and/or otherwise affect
control over the EEV 112.
[0032] The outdoor controller 126 may be carried by the outdoor
unit 104 and may be configured to receive information inputs,
transmit information outputs, and otherwise communicate with the
system controller 106, the indoor controller 124, and/or any other
device 130 via the communication bus 128 and/or any other suitable
medium of communication. In some embodiments, the outdoor
controller 126 may be configured to communicate with an outdoor
personality module 140 that may comprise information related to the
identification and/or operation of the outdoor unit 104. In some
embodiments, the outdoor controller 126 may be configured to
receive information related to an ambient temperature associated
with the outdoor unit 104, information related to a temperature of
the outdoor heat exchanger 114, and/or information related to
refrigerant temperatures and/or pressures of refrigerant entering,
exiting, and/or within the outdoor heat exchanger 114 and/or the
compressor 116. In some embodiments, the outdoor controller 126 may
be configured to transmit information related to monitoring,
communicating with, and/or otherwise affecting control over the
outdoor fan 118, a compressor sump heater, a solenoid of the
reversing valve 122, a relay associated with adjusting and/or
monitoring a refrigerant charge of the HVAC system 100, a position
of the EEV 112, and/or a position of the outdoor metering device
120. The outdoor controller 126 may further be configured to
communicate with a compressor drive controller 144 that is
configured to electrically power and/or control the compressor
116.
[0033] The HVAC system 100 is shown configured for operating in a
so-called cooling mode in which heat is absorbed by refrigerant at
the indoor heat exchanger 108 and heat is rejected from the
refrigerant at the outdoor heat exchanger 114. In some embodiments,
the compressor 116 may be operated to compress refrigerant and pump
the relatively high temperature and high pressure compressed
refrigerant from the compressor 116 to the outdoor heat exchanger
114 through the reversing valve 122 and to the outdoor heat
exchanger 114. As the refrigerant is passed through the outdoor
heat exchanger 114, the outdoor fan 118 may be operated to move air
into contact with the outdoor heat exchanger 114, thereby
transferring heat from the refrigerant to the air surrounding the
outdoor heat exchanger 114. The refrigerant may primarily comprise
liquid phase refrigerant and the refrigerant may flow from the
outdoor heat exchanger 114 to the EEV 112 through and/or around the
outdoor metering device 120 which does not substantially impede
flow of the refrigerant in the cooling mode. The EEV 112 may meter
passage of the refrigerant through the EEV 112 so that the
refrigerant downstream of the EEV 112 is at a lower pressure than
the refrigerant upstream of the EEV 112. The pressure differential
across the EEV 112 allows the refrigerant downstream of the EEV 112
to expand and/or at least partially convert to a two-phase (vapor
and gas) mixture. The two-phase refrigerant may enter the indoor
heat exchanger 108. As the refrigerant is passed through the indoor
heat exchanger 108, the indoor fan 110 may be operated to move air
into contact with the indoor heat exchanger 108, thereby
transferring heat to the refrigerant from the air surrounding the
indoor heat exchanger 108, and causing evaporation of the liquid
portion of the two-phase mixture. The refrigerant may thereafter
re-enter the compressor 116 after passing through the reversing
valve 122.
[0034] To operate the HVAC system 100 in the so-called heating
mode, the reversing valve 122 may be controlled to alter the flow
path of the refrigerant, the EEV 112 may be disabled and/or
bypassed, and the outdoor metering device 120 may be enabled. In
the heating mode, refrigerant may flow from the compressor 116 to
the indoor heat exchanger 108 through the reversing valve 122, the
refrigerant may be substantially unaffected by the EEV 112, the
refrigerant may experience a pressure differential across the
outdoor metering device 120, the refrigerant may pass through the
outdoor heat exchanger 114, and the refrigerant may reenter the
compressor 116 after passing through the reversing valve 122. Most
generally, operation of the HVAC system 100 in the heating mode
reverses the roles of the indoor heat exchanger 108 and the outdoor
heat exchanger 114 as compared to their operation in the cooling
mode.
[0035] Referring now to FIG. 2, a simplified schematic diagram of
the air circulation paths for a structure 200 conditioned by two
HVAC systems 100 is shown. In this embodiment, the structure 200 is
conceptualized as comprising a lower floor 202 and an upper floor
204. The lower floor 202 comprises zones 206, 208, and 210 while
the upper floor 204 comprises zones 212, 214, and 216. The HVAC
system 100 associated with the lower floor 202 is configured to
circulate and/or condition air of lower zones 206, 208, and 210
while the HVAC system 100 associated with the upper floor 204 is
configured to circulate and/or condition air of upper zones 212,
214, and 216.
[0036] In addition to the components of HVAC system 100 described
above, in this embodiment, each HVAC system 100 further comprises a
ventilator 146, a prefilter 148, a humidifier 150, and a bypass
duct 152. The ventilator 146 may be operated to selectively exhaust
circulating air to the environment and/or introduce environmental
air into the circulating air. The prefilter 148 may generally
comprise a filter media selected to catch and/or retain relatively
large particulate matter prior to air exiting the prefilter 148 and
entering the air cleaner 136. The humidifier 150 may be operated to
adjust a humidity of the circulating air. The bypass duct 152 may
be utilized to regulate air pressures within the ducts that form
the circulating air flow paths. In some embodiments, air flow
through the bypass duct 152 may be regulated by a bypass damper 154
while air flow delivered to the zones 206, 208, 210, 212, 214, and
216 may be regulated by zone dampers 156.
[0037] Still further, each HVAC system 100 may further comprise a
zone thermostat 158 and a zone sensor 160. In some embodiments, a
zone thermostat 158 may communicate with the system controller 106
and may allow a user to control a temperature, humidity, and/or
other environmental setting for the zone in which the zone
thermostat 158 is located. Further, the zone thermostat 158 may
communicate with the system controller 106 to provide temperature,
humidity, and/or other environmental feedback regarding the zone in
which the zone thermostat 158 is located. In some embodiments, a
zone sensor 160 may communicate with the system controller 106 to
provide temperature, humidity, and/or other environmental feedback
regarding the zone in which the zone sensor 160 is located.
[0038] While HVAC systems 100 are shown as a so-called split system
comprising an indoor unit 102 located separately from the outdoor
unit 104, alternative embodiments of an HVAC system 100 may
comprise a so-called package system in which one or more of the
components of the indoor unit 102 and one or more of the components
of the outdoor unit 104 are carried together in a common housing or
package. The HVAC system 100 is shown as a so-called ducted system
where the indoor unit 102 is located remote from the conditioned
zones, thereby requiring air ducts to route the circulating air.
However, in alternative embodiments, an HVAC system 100 may be
configured as a non-ducted system in which the indoor unit 102
and/or multiple indoor units 102 associated with an outdoor unit
104 is located substantially in the space and/or zone to be
conditioned by the respective indoor units 102, thereby not
requiring air ducts to route the air conditioned by the indoor
units 102.
[0039] Still referring to FIG. 2, the system controllers 106 may be
configured for bidirectional communication with each other and may
further be configured so that a user may, using any of the system
controllers 106, monitor and/or control any of the HVAC system 100
components regardless of which zones the components may be
associated. Further, each system controller 106, each zone
thermostat 158, and each zone sensor 160 may comprise a humidity
sensor. As such, it will be appreciated that structure 200 is
equipped with a plurality of humidity sensors in a plurality of
different locations. In some embodiments, a user may effectively
select which of the plurality of humidity sensors is used to
control operation of one or more of the HVAC systems 100.
[0040] Referring now to FIGS. 3-5, cutaway views of an electronic
expansion valve (EEV) 112 configured in a metering position,
configured in a fully open position, and configured in a fully
closed position are shown, respectively, according to embodiments
of the disclosure. The EEV 112 generally comprises a valve body
302, a side port 304, and an inline port 306. The EEV 112 further
comprises an upper valve portion 310 that extends from the valve
body 302 along an axis 320 that is coincident with the inline port
306. Generally, the valve body 302, the side port 304, the inline
port 306, and the upper valve portion 310 define a valve cavity 338
through which refrigerant may flow. The EEV 112 also comprises a
selectively movable obturator 316 connected to an obturator shaft
318 and that is substantially axially aligned with axis 320. The
obturator shaft 318 may generally be connected to a rotor 314 that
has a cylindrically-shaped exterior surface. The obturator shaft
318 may generally affix to the rotor 314 by a push nut 324. The
rotor 314 comprises a rotor magnet 326 which may be generally
affixed to the exterior surface of the rotor 314. The rotor 314 and
rotor magnet 326 are encapsulated by a rotor cover 328 that is
configured such that an open end of the rotor cover 328 mates to
the valve body 302, thereby forming a rotor cavity that provides
clearance for a longitudinal movement of the rotor 314 along axis
320.
[0041] The EEV 112 also comprises an electronically controlled
motor 330. In some embodiments, the motor 330 comprises a stepper
motor. The motor 330 radially surrounds the rotor cover 328 and is
configured to selectively change a position of the rotor 314.
Electrical command pulses applied to the motor 330 may cause
angular rotation of the rotor magnet 326. The rotor 314 is
configured with rotor threads 322 on the inner surface of the rotor
314 and the rotor threads 322 interlock with valve body threads 312
located on the outer surface of the upper valve portion 310. The
interlocking rotor threads 322 and valve body threads 312 are
configured to allow the rotor 314 to rotate about the upper valve
portion 310, such that the rotor 314 moves longitudinally along the
axis 320, thereby driving the obturator 316 similarly along the
axis 320. When in a metering position, the obturator 316 is
generally configured to restrict refrigerant flow through the valve
cavity 338 based on the longitudinal position of the obturator 316.
The obturator 316 may be configured in a conical or frustoconical
shape to interface with a complimentary valve seat 308, such that
when the obturator 316 is positioned within the valve seat 308,
refrigerant flow through the valve cavity 338 from the side port
304 to the inline port 306 is restricted. While in some embodiments
the obturator 316 may comprise a conical or frustoconical shape, in
alternative embodiments an obturator 316 or a complimentary valve
seat 308 may comprise any other suitable shape for restricting or
preventing flow of refrigerant through the valve cavity 338. When
the obturator 316 is driven into the valve seat 308 at a fully
closed position as shown in FIG. 5, flow of refrigerant through the
valve cavity 338 may be prevented.
[0042] The EEV 112 also comprises a first sensor 332 and a second
sensor 334. The first sensor 332 and the second sensor 334 are
generally longitudinally offset relative to each other along axis
320. The longitudinal offset distance between the first sensor 332
and the second sensor 334 may generally relate to a longitudinal
travel distance of the rotor 314 along axis 320 between the fully
open position (shown in FIG. 4) to the fully closed position (shown
in FIG. 5). In some embodiments, the first sensor 332 and the
second sensor 334 may be aligned angularly about axis 320. In other
embodiments, the first sensor 332 and the second sensor 334 may be
offset angularly relative to each other about axis 320 while still
maintaining a longitudinal displacement along axis 320. In other
embodiments, the EEV 112 may comprise plurality of sensors disposed
longitudinally along axis 320 with various offset distances
relative to each other. In yet other embodiments, an EEV 112 may
comprise a plurality of sensors disposed longitudinally along axis
320 and offset angularly relative to each other at various
intervals about axis 320. In yet other embodiments, an EEV 112 may
comprise a plurality of sensors disposed laterally at various
distances from the axis 320. Generally, the sensors are enclosed
within the rotor cover 328 and located in the rotor cavity 336.
[0043] In some embodiments, the first sensor 332 and second sensor
334 may comprise Hall Effect sensors. In alternative embodiments,
the first sensor 332 and second sensor 334 may comprise
electro-optical sensors. In yet other embodiments, the first sensor
332 and second sensor 334 may comprise electronic proximity
(inductive) sensors. Generally, the first sensor 332 and second
sensor 334 may be electrically coupled to the indoor EEV controller
138. In other embodiments, the first sensor 332 and the second
sensor 334 may be electrically coupled to the indoor controller
124. The first sensor 332 and the second sensor 334 may generally
be configured to communicate with the indoor EEV controller 138
and/or the indoor controller 124. In some embodiments, the first
sensor 332 and the second sensor 334 may be configured to transmit
information about the EEV 112 to the indoor EEV controller 138
and/or the indoor controller 124.
[0044] Still referring to FIGS. 3-5, the first sensor 332 and the
second sensor 334 may be configured to detect the proximity of the
rotor magnet 326. During operation, the rotor 314 may generally be
positioned in a metering position as shown in FIG. 3. In a metering
position, the obturator 316 partially restricts flow of refrigerant
through the valve cavity 338. The longitudinal position of the
obturator 316 may be adjusted during operation to allow more or
less refrigerant flow through the EEV 112. When more refrigerant
flow is required by the HVAC system 100, the EEV 112 may
selectively move the obturator 316 to an alternate metering
position relatively more open, thereby retracting the obturator
along axis 320 and away from the valve seat 308. When less
refrigerant flow is required by the HVAC system 100, the EEV 112
may selectively move the obturator 316 to an alternate metering
position relatively more closed, thereby moving the obturator along
axis 320 and toward the valve seat 308.
[0045] As the obturator 316 moves toward a fully open position
(shown in FIG. 4), the rotor 314 moves in a longitudinal direction
along axis 320 and approaches the first sensor 332. This movement
causes the rotor magnet 326 to also move closer to the first sensor
332. The first sensor 332 is configured to detect the proximity of
the rotor magnet 326 such that a higher magnetic field is detected
by the first sensor 332 as the rotor magnet 326 approaches the
first sensor 332. The first sensor 332 is generally configured to
detect a highest amplitude of magnetic field when the obturator 316
is at the fully open position as shown in FIG. 4. Contrarily, as
the rotor magnet 326 approaches the first sensor 332, the rotor
magnet 326 increases its distance from the second sensor 334, such
that the second sensor 334 detects a decreasing magnetic field from
the rotor magnet 326. The second sensor 334 is generally configured
to detect a lowest magnetic field when the obturator 316 is in the
fully open position as shown in FIG. 4. The first sensor 332 and
the second sensor 334 may generally transmit information about the
position of the rotor 314, the rotor magnet 326, and/or the
obturator 316 to the EEV controller 138.
[0046] As the EEV 112 moves toward a fully closed position (shown
in FIG. 5), the rotor 314 moves in a longitudinal direction along
axis 320 and moves closer to the second sensor 334. This movement
causes the rotor magnet 326 to also move closer to the second
sensor 334. The second sensor 334 is also configured to detect the
proximity of the rotor magnet 326 such that an increasing magnetic
field is detected by the second sensor 334 as the rotor magnet 326
moves closer to the second sensor 334. The second sensor 334 is
generally configured to detect the highest amplitude of magnetic
field at the fully closed position as shown in FIG. 5. Contrarily,
as the rotor magnet 326 moves closer to the second sensor 334, the
rotor magnet 326 increases its distance from the first sensor 332,
such that the first sensor 332 detects a decreasing magnetic field
from the rotor magnet 326. The first sensor 332 is generally
configured to detect the lowest amplitude of magnetic field at the
fully closed position as shown in FIG. 5. Thus, as the rotor magnet
326 moves closer to the second sensor 334, the first sensor 332 and
the second sensor 334 may generally transmit information about the
position of the rotor 314, the rotor magnet 326, and/or the
obturator 316 to the EEV controller 138.
[0047] In some embodiments, the information transmitted by the
first sensor 332 and the second sensor 334 may generally be used to
determine the relative operating position of the obturator 316
along the axis 320. In general, this may be accomplished by
comparing relative values of information sent to the indoor EEV
controller 138 by the first sensor 332 and the second sensor 334.
For example, when a maximum output voltage of either sensor 332,
334 is determined to be 5 volts when the rotor magnet 326 is
adjacent to either the first sensor 332 or the second sensor 334,
the first sensor 332 may output a signal of 5 volts when the rotor
magnet 326 is adjacent to the first sensor 332 at the fully open
position as shown in FIG. 4. Alternatively, when the obturator 316
is in the closed position as shown in FIG. 5, the rotor magnet 326
may be longitudinally aligned to the second sensor 334, thereby
causing the second sensor 334 to output a signal of 5 volts. When
the obturator 316 is positioned in either a fully open position as
shown in FIG. 4 or a fully closed position as shown in FIG. 5, the
output of the sensor that is not longitudinally aligned with the
rotor magnet 326 may be configured to be 0 volts. Alternatively, a
sensor 332, 334 that is not longitudinally aligned with the rotor
magnet 326 may output a nominal voltage of about 1 volt, so that
when the obturator 316 is in the fully open position as shown in
FIG. 4, the output of the first sensor 332 may be 5 volts, while
the output of the second sensor 334 may be 1 volt. Alternatively,
when the obturator 316 is in the fully closed position as shown in
FIG. 5, the output of the second sensor 334 may be 5 volts, while
the output of the first sensor 332 may be 1 volt.
[0048] As shown in FIG. 3, when the obturator 316 is positioned in
a metering state, the first sensor 332 and the second sensor 334
may output voltages that are relative to the location of the
obturator 316. For example, continuing with the previous example
and assuming a linear relationship between the longitudinal
alignment of the rotor magnet 326 with a sensor 332, 334, output
values for the first sensor 332 and second sensor 334 may both
register 3 volts when the EEV 112 is operating at capacity half
open position. Additionally, the same EEV 112 operating at 3/4 open
position may produce an output voltage of 4 volts for the first
sensor 332 and 2 volts for the second sensor 334, still assuming a
linear relationship. In some embodiments, the EEV controller 138
and/or indoor controller 124 may comprise a table of values for
determining the instantaneous operating position the obturator 316.
The table comprises predetermined relationships between the
position of the obturator 316 and the corresponding output voltages
of the first sensor 332 and the second sensor 334. It should be
noted that while only one example is provided to illustrate the
functionality of the first sensor 332 and second sensor 334 of the
EEV 112, the specific output voltages of sensors 332 and 334 may be
based on characteristics of the EEV 112, including, but not limited
to, the longitudinal travel distance of the rotor 314 along the
axis 320, the longitudinal offset distance of the first sensor 332
relative to the second sensor 334 along the axis 320, a size and/or
strength of the rotor magnet 326, and/or the dimensions of the
rotor cavity 336 as determined by the configuration of the rotor
cover 328.
[0049] In addition to determining the operating position of the
obturator 316, the information sent by the first sensor 332 and the
second sensor 334 may be used to determine a longitudinal and/or
angular direction of movement of the obturator 316 as measured
along the axis 320. As the obturator 316 travels upward along the
axis 320 and approaches the first sensor 332, the first sensor 332
may continuously detect an increasing magnetic field strength
attributable to the changing position of the rotor magnet 326. In
turn, the first sensor 332 will output increasing voltage values as
the rotor 314 moves closer to the first sensor and opens the EEV
112. Similarly, as the rotor 314 travels upward along the axis 320
and consequently away from the second sensor 334, the second sensor
334 may continuously experience a decreasing magnetic field
strength exhibited by the rotor magnet 326. Thus, the second sensor
334 may continuously output a decreasing voltage as the rotor 314
travels away from the second sensor 334. These ever-changing
voltage outputs from the first sensor 332 and the second sensor 334
may generally be used to determine at least one of a longitudinal
and/or angular movement of the obturator 316.
[0050] In some embodiments, knowing the position and direction of
movement of the rotor 314 in an EEV 112 may be useful in verifying
correct function of the motor 330 of an EEV 112. In other
embodiments, position information rendered by the first sensor 332
and the second sensor 334 may be used to calibrate the obturator of
the EEV 112. Currently, an EEV 112 must reset itself to calibrate,
which requires fully opening or fully closing the EEV 112 as shown
in FIG. 4 and FIG. 5, respectively. Position feedback of the EEV
112 as determined by the first sensor 332 and the second sensor 334
may thus eliminate the requirement for an EEV 112 to fully open or
fully close to calibrate itself, thus allowing calibration of an
EEV 112 at any position. Eliminating the current requirement to
reset an EEV may also allow calibration of the EEV 112 as well as
faster startup times for an HVAC system. In some embodiments,
position information may be used to control the position of an
obturator 316 rather than relying on the function of a motor 330 of
an EEV 112 to control the position. In this instance, feedback from
the first sensor 332 and second sensor 334 may be sent to the
indoor EEV controller 138. Based on a subcooling model or other
parameters of the HVAC system 100, the EEV controller 138 may then
adjust the position of the obturator 316 accordingly. Furthermore,
in some embodiments, position information supplied by the first
sensor 332 and second sensor 334 may also be useful in monitoring
steady state operation of the HVAC system 100.
[0051] A change in the output voltage of the first sensor 332 and
the second sensor 334 may also be used to determine linear speed of
the obturator 316 as measured along the axis 320. As stated, the
position of the obturator 316 may be associated with particular
voltage outputs of the first sensor 332 and second sensor 334. As
stated, the direction of movement of the obturator 316 may also be
calculated from the output voltages rendered by the first sensor
332 and the second sensor 334. Accordingly, the changes in the
output voltages from the first sensor 332 and the second sensor 334
may be determined over a particular time increment to determine the
instantaneous speed of the obturator 316 traveling in a linear
direction along the axis 320. In some embodiments, determining the
speed of the obturator 316 travel along the axis 320 may increase
controllability of the EEV 112. In other embodiments, it may be
useful in monitoring the function of the motor 330 of the EEV 112.
For example, an EEV 112 is generally subject to the accumulation of
dirt and/or corrosion when subjected to operating conditions. A
slow moving obturator 316 could alter performance of the HVAC
system 112 and further cause a delay in the HVAC system 100
realizing the effects of adjustment of the EEV 112. Knowledge of a
dirty, corroded EEV 112 could warrant replacement and/or cleaning
to restore system peak performance. Thus, in some embodiments,
determining the linear speed of an obturator 316 along axis 320 may
serve as a troubleshooting function.
[0052] In addition to determining the position, direction of
movement, and linear speed of the obturator 316, rotational speed
(RPM) and angular displacement may also be determined based on the
outputs provided by the first sensor 332 and second sensor 334.
This is accomplished by utilizing an algorithm to translate linear
speed into rotational speed based on a given thread pitch of the
valve body threads 312 and the rotor threads 322. Furthermore, if a
distance traveled by the obturator 316 is known along the axis 320,
the angular displacement may also be determined based on the given
thread pitch of the valve body threads 312 and the rotor threads
322. For example, if the thread pitch is 0.050'' and the linear
distance traveled by the rotor 314 is determined to be 0.025'',
then it can be determined that the rotor 314 made one half
rotation, equal to 180 degrees. In some embodiments, the first
sensor 332 and the second sensor 334 may be aligned longitudinally.
However, in other embodiments, the first sensor 332 and the second
sensor 334 may be offset angularly with respect to axis 320 based
on the configuration of the EEV 112. In some embodiments,
determining the angular speed and/or angular displacement through
the first sensor 332 and the second sensor 334 may increase the
controllability of the obturator 316. In other embodiments,
determining angular speed and/or angular displacement may be useful
to verify the correct obturator 316 location control of an EEV 112.
In yet other embodiments, angular speed and/or angular displacement
may be used to calibrate an EEV 112. Furthermore, in other
embodiments, rotational speed and/or angular displacement may also
be used to control the obturator 316 rather than relying on the
motor 330 alone. As such, EEV 112 may add functionality and
accuracy to the operation of the HVAC system 100.
[0053] Referring now to FIG. 6, a cutaway view of an EEV 400 is
shown according to an embodiment of the disclosure. It should be
noted that EEV 400 is substantially similar to EEV 112. EEV 400
comprises a valve body 402, side port 404, inline port 406, valve
seat 408, upper valve portion 410, valve body threads 412, rotor
414, obturator 416, obturator shaft 418, axis 420, rotor threads
422, push nut 424, rotor magnet 426, rotor cover 428, motor 430,
first sensor 432, second sensor 434, rotor cavity 436, and valve
cavity 438. Depending on the configuration of the HVAC system 100,
the first sensor 432 and the second sensor 434 may generally be
configured to communicate with the indoor EEV controller 138 and/or
the indoor controller 124. As with EEV 112, the first sensor 432
and the second sensor 434 are generally disposed longitudinally
relative to each other along axis 420. In some embodiments, the
first sensor 432 and the second sensor 434 may be aligned
longitudinally. However, in other embodiments, the first sensor 432
and the second sensor 434 may be offset angularly about axis 420
based on the configuration of the EEV 112.
[0054] EEV 400 generally comprises a plurality of triggers 440. In
some embodiments, the triggers 440 may comprise magnets. In other
embodiments, the triggers 440 may comprise inductors. In yet other
embodiments, the triggers 440 may comprise an optical catalyst
capable of optical detection (i.e. contrasting color). The triggers
440 are generally carried by the rotor magnet 426 and displaced
longitudinally along the rotor magnet 426 substantially parallel to
axis 420. The triggers 440 are generally also configured to
surround the rotor 414 and/or rotor magnet 426 radially, such that
each trigger 440 at a different longitudinal location as determined
along the axis 420 comprises a single element. In other
embodiments, however, each trigger 440 at a different longitudinal
location as determined along the axis 420 may be divided into a
plurality of substantially similar-sized adjacent pieces that
radially surround the rotor 414 and/or rotor magnet 426 to form a
single trigger 440. The placement of the triggers 440 within the
rotor magnet 426 or on the outer surface of the rotor magnet 426
may be determined by the configuration of the EEV 400, including
but not limited to, the strength of the rotor magnet 426, the
strength of the triggers 440, and the proximity of the rotor magnet
426 to the rotor cover 428. In some embodiments, the triggers 440
may be located along the inner part of the rotor magnet 426,
substantially adjacent to the rotor 414 as shown in FIG. 6. In
other embodiments, the triggers 440 may be located substantially
towards the outer surface of the rotor magnet 426, such that the
outermost surface of the triggers 440 is substantially aligned with
the outer surface of the rotor magnet 426. In yet other
embodiments, the triggers 440 may be located at any location within
the rotor magnet 426 between the inner surface of the rotor magnet
426 substantially adjacent to the rotor 414 and the outer surface
of the rotor magnet 426. In alternative embodiments, the triggers
440 may be placed on the outer surface of the rotor magnet 426 and
extend outward from the outer surface of the rotor magnet 426
towards the rotor cover 428, thus protruding from the rotor magnet
426. In yet other embodiments, the EEV 400 may comprise a plurality
of triggers 440 substantially adjacent to each other, such that the
trigger 440 configuration forms the rotor magnet 426.
[0055] Still referring to FIG. 6, the triggers 440 may generally be
configured such that trigger 440' comprises a highest magnetic
strength, triggers 440' on the top and bottom limits of the
configuration comprise a lowest magnetic strength, and triggers
440'' located between trigger 440' and each of triggers 440'''
comprise an intermediate magnetic strength between that of trigger
440' and trigger 440'. While only one intermittent strength trigger
440'' is shown in FIG. 6 between highest magnetic strength trigger
440' and each of the lowest magnetic strength triggers 440''', in
some embodiments, the EEV 400 may comprise a plurality of
intermediate magnetic strength triggers 440'' located between the
highest strength trigger 440' and each of the lowest strength
triggers 440'''. In embodiments where the EEV 400 comprises a
plurality of intermediate strength triggers 440'' between the
highest strength trigger 400' and the lowest strength trigger
440'', the plurality of intermediate strength triggers 440'' may
generally be configured in order of decreasing magnetic strength
starting with the intermediate strength triggers 440'' located
closest to the highest strength trigger 440' and radiating outward
towards either of the lowest strength triggers 440''' along the
axis 320 in a configuration of decreasing magnetic strength.
[0056] The first sensor 432 and second sensor 434 are configured to
detect the pattern of magnetic fields emitted from the trigger 440
configuration. For illustration purposes, the top of the trigger
440 configuration means the furthest distance along axis 420
relative to the valve seat 408, and the bottom of the trigger 440
configuration means the closest distance along axis 420 relative to
the valve seat 408. The first sensor 432 may generally be
configured to detect the highest strength trigger 440' when the
obturator 416 is in the fully open position as shown in FIG. 6 such
that the first sensor 432 outputs the highest known voltage for the
trigger 440 configuration. Additionally, the second sensor 434 may
generally be configured to detect the lowest strength trigger
440''' located at the bottom of the trigger 440 configuration when
the obturator 416 is in the fully open position as shown in FIG. 6
and thus output the lowest known voltage for the trigger 440
configuration. At the fully closed position, the second sensor 434
may generally be configured to detect the highest strength trigger
440', thus outputting the highest known voltage for the trigger 440
configuration, and the first sensor 432 may generally be configured
to detect the lowest strength trigger 440''' located at the top of
the trigger 440 configuration, thus outputting the lowest known
voltage for the trigger 440 configuration. From the open position
as shown in FIG. 6, when the EEV 400 begins to close, the rotor 414
will rotate about the axis 420 driving the obturator 416 towards
the valve seat 408. As the EEV 400 moves towards the closed
position, the first sensor 432 will begin to detect intermediate
strength trigger 440'' located above highest strength trigger 440'
thus outputting a lower voltage than when it was detecting the
highest strength trigger 440'. The second sensor 434 will begin to
detect trigger 440'' located below highest strength trigger 440',
thus outputting a higher voltage than when the second sensor 434
was detecting the lowest strength sensor 440''' at the bottom of
the trigger 440 configuration. Accordingly, the first sensor 432
will continue to detect a decreasing strength magnetic field and
output a decreasing voltage, and the second sensor 434 will
continue to detect an increasing strength magnetic field and output
an increasing voltage as the obturator 416 closes. Contrarily, the
first sensor 432 will detect an increasing strength magnetic field
and output an increasing voltage, and the second sensor 434 will
detect a decreasing strength magnetic field and output a decreasing
voltage as the obturator 416 opens.
[0057] In other embodiments, the triggers 440 may comprise a
different configuration, where a highest strength trigger 440' is
located at the top and bottom of the trigger 440 configuration, and
the lowest magnetic strength trigger 440''' is located in the
center of the configuration. In some embodiments where the lowest
strength trigger 440''' is located in the center of the trigger 440
configuration, and wherein the EEV 400 comprises a plurality of
intermediate strength triggers 440'', the intermediate strength
triggers 440'' may be arranged between the lowest strength trigger
440''' and each of the highest strength triggers 440' in an order
of increasing magnetic strength starting with the intermediate
strength trigger 440'' most adjacent to lowest strength trigger
440''' and radiating towards each of the highest strength triggers
440' located at the top and bottom of the trigger 440
configuration.
[0058] In such embodiments, at the obturator 316 open position, the
first sensor 432 may be configured to detect the lowest magnetic
strength trigger 440''' located in the center of the trigger 440
configuration, and the second sensor 434 may be configured to
detect the highest strength trigger 440' located at the bottom of
the trigger 440 configuration. Accordingly, as the obturator 416
closes, the first sensor 432 may be configured to detect an
increasing strength magnetic field, and the second sensor 434 may
be configured to detect a decreasing strength magnetic field, until
the EEV 400 reaches the fully closed position, wherein the first
sensor 432 would detect the highest strength trigger 440' located
at the top of the trigger 440 configuration and the second sensor
434 would detect the lowest strength trigger 440''' located in the
center of the trigger 440 configuration. In yet other embodiments,
the triggers 440 may comprise a substantially similar magnetic
strength. Such triggers 440 may amplify the magnetic field emitted
from the rotor to provide enhanced detection by the first sensor
432 and the second sensor 434. In alternative embodiments, the
triggers 440 may comprise a non-linear pattern configured such that
the first sensor 432 and the second sensor 434 may detect
exaggerated increases and/or decreases in magnetic field strength
as the obturator 416 changes position. For example, the
configuration from top to bottom could comprise the following
trigger 440 configuration: 440'' (Top); 440'; 440'''; 440'
(Center); 440'''; 440'; 440'' (Bottom). Large variances in magnetic
field strength detected by the first sensor 432 and the second
sensor 434 may provide a wider range of output voltages from the
sensors and thus increase the accuracy of measurement of the EEV
400 position and other functional parameters. In yet other
embodiments, the EEV 400 may comprise only three triggers 440
having one highest strength trigger 440' and two of either
intermediate triggers 440'' or lowest strength triggers 440'
arranged substantially similarly to any of the previously described
embodiments, wherein the first sensor 432 and the second sensor 434
are configured substantially similar to previously described
embodiments.
[0059] As with EEV 112, the output voltages from the first sensor
432 and the second sensor 434 may be used to determine the position
of the obturator 416 of the EEV 400. Known output voltages may be
associated with each trigger 440, such that at any given position
of the EEV 400, the output voltages from the first sensor 432 and
the second sensor 434 may be used to determine the position of the
triggers 440 and consequently the obturator 416. Such known
voltages may be stored in the EEV controller 138 or the indoor
controller 124 and used to determine the position of the obturator
416. Utilizing triggers 440 that comprise different magnetic field
strengths may also produce a more significant change in the
magnetic field detected by the first sensor 432 and the second
sensor 434 as the EEV 400 changes position. Consequently, smaller
increments of movement may be able to be detected, thus enabling
more accurate detection of the position of the EEV 400.
[0060] Furthermore, changes in the magnetic field strength emitted
by the triggers 440 may also be used to determine the direction of
movement. For example, as in FIG. 6, the first sensor 432 may be
configured to detect the highest strength trigger 440' at the fully
open position and the second sensor 434 may be configured to detect
the lowest strength trigger 440''' at the fully open position.
Thus, as the first sensor 432 detects a decreasing magnetic field
strength and the second sensor 434 detects an increasing magnetic
field strength as the EEV 400 closes, the first sensor 432 will
output continuously decreasing voltages, and the second sensor 434
will output continuously increasing voltages. Similarly to EEV 112,
the respective voltage outputs of each sensor 432, 434 may then be
used to determine the exact position of the obturator 416, and the
change in the voltage outputs of each sensor may be used to
determine the direction of movement of the obturator 416. Because
EEV 400 is substantially similar to EEV 112, the respective voltage
outputs of the first sensor 432 and second sensor 434 in EEV 400
may be used to determine the exact position of the obturator 416.
Additionally, output voltages of the first sensor 432 and the
second sensor 434 may also be used to determine direction, linear
speed, angular rotational speed, and angular displacement of the
obturator 416 in the same manner disclosed in EEV 112. The triggers
440 comprising different magnetic field strengths may, however,
provide more accurate sensing of such parameters due to the higher
magnitude changes that are detected by the first sensor 432 and the
second sensor 434 for smaller increments of movement of the EEV
400. Thus, EEV 400 may also provide the same benefits to enhancing
HVAC system 100 operation.
[0061] Referring now to FIG. 7, a cutaway view of an EEV 500 is
shown according to an embodiment of the disclosure. It should be
noted that EEV 500 is substantially similar to EEV 400. EEV 500
comprises a valve body 502, side port 504, inline port 506, valve
seat 508, upper valve portion 510, valve body threads 512, rotor
514, obturator 516, obturator shaft 518, axis 520, rotor threads
522, push nut 524, rotor magnet 526, rotor cover 528, motor 530,
first sensor 532, second sensor 534, rotor cavity 536, valve cavity
538, and a plurality of triggers 540. Depending on the
configuration of the HVAC system 100, the first sensor 532 and the
second sensor 534 may generally be configured to communicate with
the indoor EEV controller 138 and/or the indoor controller 124. As
with EEV 400, the first sensor 532 and the second sensor 534 are
generally longitudinally offset relative to each other along axis
520. In some embodiments, the first sensor 532 and the second
sensor 534 may be aligned longitudinally. However, in other
embodiments, the first sensor 532 and the second sensor 534 may be
offset angularly based on the configuration of the EEV 500.
[0062] EEV 500 generally comprises a rotor extension 542. The rotor
extension 542 may generally extend from the top surface of the
rotor 514 along axis 520 and comprise a cylindrical shape axially
aligned with axis 520. In some embodiments, the rotor extension 542
may comprise an elongated portion of the rotor 514 that extends
upward along the axis 520 and beyond the top of the rotor magnet
526. In other embodiments, the rotor extension 542 may comprise a
separate component that is permanently secured to the rotor 514
such that any electronic expansion valve may be configured to
accept the rotor extension 542. In some instances, the rotor
extension 542 may require an elongated rotor cover 528 in order to
fully encapsulate the rotor 514 and the rotor extension 542. EEV
500 may also comprise a rotor extension cavity 544. In some
embodiments, the rotor extension cavity 544 may provide clearance
for the push nut 524. In other embodiments, the obturator shaft 518
may extend into the rotor extension cavity 544, where the push nut
524 may secure the obturator shaft 518 to the top of the rotor
extension 542.
[0063] The trigger 540 configuration of EEV 500 may be
substantially similar to any of the enumerated embodiments of EEV
400. Additionally, the first sensor 532 and second sensor 534
configuration may also be substantially similar to any of the
enumerated embodiments of EEV 400. The difference between EEV 500
and EEV 400 is embodied in that triggers 540 in EEV 500 are carried
by the rotor extension 542 as opposed to the triggers 440 in EEV
400 being carried by the rotor magnet 426. However, similarly to
EEV 400, the respective voltage outputs of the first sensor 532 and
second sensor 534 in EEV 500 may be used to determine the position
of the EEV 500. Additionally, as with EEV 400, output voltages of
the first sensor 532 and the second sensor 532 may also be used to
determine direction, linear speed, angular rotational speed, and
angular displacement of obturator 516. Thus, EEV 500 may also
provide substantially similar benefits to enhancing HVAC system 100
operation.
[0064] Referring now to FIG. 8, a cutaway view of an EEV 600 is
shown according to an embodiment of the disclosure. It should be
noted that EEV 600 is substantially similar to EEV 500. EEV 600
comprises a valve body 602, side port 604, inline port 606, valve
seat 608, upper valve portion 610, valve body threads 612, rotor
614, obturator 616, obturator shaft 618, axis 620, rotor threads
622, push nut 624, rotor magnet 626, rotor cover 628, motor 630,
first sensor 632, second sensor 634, rotor cavity 636, valve cavity
638, and a plurality of triggers 640. Depending on the
configuration of the HVAC system 100, the first sensor 632 and the
second sensor 634 may generally be configured to communicate with
the indoor EEV controller 138 and/or the indoor controller 124. As
with EEV 500, the first sensor 632 and the second sensor 634 are
generally longitudinally offset relative to each other along axis
620. In some embodiments, the first sensor 632 and the second
sensor 634 may be aligned longitudinally along axis 620. However,
in other embodiments, the first sensor 632 and the second sensor
634 may be offset angularly based on the configuration of the EEV
600.
[0065] While EEV 600 may be substantially similar to EEV 500, EEV
600 does not comprise a rotor extension similar to rotor extension
542 that carries triggers 540 as in EEV 500. Instead the triggers
640 of EEV 600 may generally be carried by the rotor 614. The
triggers 640 are generally displaced longitudinally from the rotor
magnet 626 along the axis 620 such that the triggers 640 are
located below the rotor magnet 626. The trigger 640 configuration
of EEV 600 may be substantially similar to any of the enumerated
embodiments of EEV 500. Thus, in some embodiments, the triggers 640
may be embedded within a portion of the rotor 614. In other
embodiments, the triggers 640 may be located on the outer surface
of the rotor 614 and extend outward from the outer surface of the
rotor 614 towards the rotor cover 628, thus protruding from the
rotor 614. Additionally, the first sensor 632 and second sensor 634
configuration may also be substantially similar to any of the
enumerated embodiments of EEV 500. Therefore, similarly to EEV 500,
the respective voltage outputs of the first sensor 632 and second
sensor 634 in EEV 600 may be used to determine the position of the
EEV 600. Additionally, as with EEV 500, output voltages of the
first sensor 632 and the second sensor 634 may also be used to
determine direction, linear speed, angular rotational speed, and
angular displacement of obturator 616. Thus, EEV 600 may also
provide substantially similar benefits to enhancing HVAC system 100
operation.
[0066] Referring now to FIG. 9, a partial cutaway view of an EEV
700 is shown according to an embodiment of the disclosure. It
should be noted that EEV 700 is substantially similar to EEV 600.
EEV 700 comprises a valve body 702, side port 704, inline port 706,
valve seat 708, upper valve portion 710, valve body threads 712,
rotor 714, obturator 716, obturator shaft 718, axis 720, rotor
threads 722, push nut 724, rotor magnet 726, rotor cover 728, motor
730, first sensor 732, second sensor 734, rotor cavity 736, valve
cavity 738, and a plurality of triggers 740. Depending on the
configuration of the HVAC system 100, the first sensor 732 and the
second sensor 734 may generally be configured to communicate with
the indoor EEV controller 138 and/or the indoor controller 124. As
with EEV 600, the first sensor 732 and the second sensor 734 are
generally longitudinally offset relative to each other along axis
720. In some embodiments, the first sensor 732 and the second
sensor 734 may be offset angularly. However, in other embodiments,
the first sensor 732 and the second sensor 734 may be aligned
vertically depending on the configuration off the EEV 700.
[0067] As in EEV 600, the triggers 740 in EEV 700 may also be
generally carried by the rotor 714. Thus, in some embodiments, the
triggers 740 may be embedded within a portion of the rotor 714. In
other embodiments, the triggers 740 may be placed on the outer
surface of the rotor 714 and extend outward from the outer surface
of the rotor 714 towards the rotor cover 728, thus protruding from
the rotor 714. However, EEV 700 generally comprises a trigger 740
configuration wherein the triggers 740 are dispersed angularly
around the rotor 714 and configured in a helical pattern that is
coincidental with the thread pitch of the rotor 714 such that when
the rotor 714 rotates about axis 720, adjacent triggers 740 pass a
position substantially adjacent to the first sensor 732 and/or the
second sensor 734. The triggers 740 may generally be configured
such that trigger 740' comprises the highest magnetic strength,
trigger 740''' comprises the lowest magnetic strength, and triggers
740'' located between highest strength trigger 740' and each of the
triggers 740'' comprise intermediate magnetic strengths between
that of highest strength trigger 740' and lowest strength trigger
740'''. The plurality of intermediate strength triggers 740'' may
generally be configured in order of decreasing magnetic strength in
a helical pattern around the rotor 714 and coincidental with the
thread pitch of the rotor 714 starting with the intermediate
strength trigger 740'' located closest to the highest strength
trigger 740' and continuing in the helical pattern around the rotor
714 up to the lowest strength trigger 740'''.
[0068] The first sensor 732 and second sensor 734 are configured to
detect the pattern of magnetic fields emitted from the trigger 740
configuration as the rotor 714 rotates about axis 720 and
subsequent triggers 740 pass the first sensor 732 and the second
sensor 734. The second sensor 734 may generally be configured to
detect the highest strength trigger 740' located at the bottom of
the trigger 740 configuration when the obturator 716 is in the
fully open position as shown in FIG. 9 and thus output a lowest
known voltage for the trigger 740 configuration. Additionally the
first sensor 732 may generally be offset at an angular displacement
from the second sensor 734 and configured to detect an intermediate
strength trigger 740'' when the EEV 700 is in the fully open
position as shown in FIG. 9 such that the first sensor 732 outputs
a known voltage for that specific trigger 740 configuration. At the
fully closed position, the first sensor 732 may generally be
configured to detect the lowest strength trigger 740''' located at
the top of the trigger 740 configuration, thus outputting a lowest
known voltage for the trigger 740 configuration, and the second
sensor 734 may generally be configured to detect a known
intermediate strength trigger 740'', thus outputting a specific
known voltage associated with that intermediate trigger 740'' in
the trigger 740 configuration. From the open position as shown in
FIG. 9, when the obturator 716 begins to close, the rotor 714 will
rotate about the axis 720 driving the obturator 716 towards the
valve seat 708. As the obturator 716 moves towards the closed
position, the second sensor 734 will begin to detect subsequent
intermediate strength triggers 740'' located above highest strength
trigger 740' and in a helical pattern coincidental with the thread
pitch of the rotor 714, thus outputting continuously decreasing
voltages. The first sensor 734 will also detect subsequent lower
strength intermediate strength triggers 740'', thus also outputting
continuously decreasing voltages. Contrarily, both sensors 732, 734
will detect an increasing strength magnetic field and output
increasing voltages as the obturator 716 opens.
[0069] In some embodiments, the triggers 740 may comprise a
different configuration, wherein a highest strength trigger 740' is
located at the top of the trigger 740 configuration, and the lowest
magnetic strength trigger 740''' is located at the bottom of the
configuration, wherein the intermediate strength triggers 740'' are
arranged in order of increasing magnetic strength starting at the
bottom lowest strength trigger 740''' and angularly dispersed in a
helical pattern coincidental with the thread pitch of the rotor
714. In other embodiments, the triggers 740 may comprise a
non-linear pattern configured such that the first sensor 732 and
the second sensor 734 may detect exaggerated increases and/or
decreases in magnetic field strength as the obturator 716 changes
position. In yet other embodiments, the triggers 740 may comprise
any configuration as enumerated in previously disclosed
embodiments, such that the respective output voltages from the
first sensor 732 and the second sensor 734 may be used to determine
the position of the obturator 716. Known output voltages may
generally be associated with each trigger 740, such that at any
given position of the EEV 700, the output voltages from the first
sensor 732 and the second sensor 734 may be used to determine the
position of the obturator 716 and consequently the EEV 700.
Additionally, as with EEV 600, output voltages of the first sensor
732 and the second sensor 734 may also be used to determine
direction, linear speed, angular rotational speed, and angular
displacement of obturator 716. Accordingly, EEV 700 may also
provide substantially similar benefits to enhancing HVAC system 100
operation.
[0070] At least one embodiment is disclosed and variations,
combinations, and/or modifications of the embodiment(s) and/or
features of the embodiment(s) made by a person having ordinary
skill in the art are within the scope of the disclosure.
Alternative embodiments that result from combining, integrating,
and/or omitting features of the embodiment(s) are also within the
scope of the disclosure. Where numerical ranges or limitations are
expressly stated, such express ranges or limitations should be
understood to include iterative ranges or limitations of like
magnitude falling within the expressly stated ranges or limitations
(e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater
than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a
numerical range with a lower limit, R.sub.l, and an upper limit,
R.sub.u, is disclosed, any number falling within the range is
specifically disclosed. In particular, the following numbers within
the range are specifically disclosed:
R=R.sub.l+k*(R.sub.u--.sub.l), wherein k is a variable ranging from
1 percent to 100 percent with a 1 percent increment, i.e., k is 1
percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50
percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97
percent, 98 percent, 99 percent, or 100 percent. Unless otherwise
stated, the term "about" shall mean plus or minus 10 percent of the
subsequent value. Moreover, any numerical range defined by two R
numbers as defined in the above is also specifically disclosed. Use
of the term "optionally" with respect to any element of a claim
means that the element is required, or alternatively, the element
is not required, both alternatives being within the scope of the
claim. Use of broader terms such as comprises, includes, and having
should be understood to provide support for narrower terms such as
consisting of, consisting essentially of, and comprised
substantially of. Accordingly, the scope of protection is not
limited by the description set out above but is defined by the
claims that follow, that scope including all equivalents of the
subject matter of the claims. Each and every claim is incorporated
as further disclosure into the specification and the claims are
embodiment(s) of the present invention.
* * * * *