TECHNICAL FIELD
[0001] This disclosure relates to a method of controlling a vapour-compression system for
circulating a working fluid. The disclosure also relates to a vapour-compression system
comprising a controller which is configured to carry out such a method.
BACKGROUND
[0002] The increasing relevance of active thermal management in hybrid and electric vehicles
has led to a focus on the development of improved control strategies for vapour-compression
systems. A typical vapour-compression system may include a compressor, an expansion
valve, an evaporator configured to provide cooling to a thermal source and a condenser/cooler
configured to provide heating to a thermal sink. Some known control strategies include
modulating a flow of fluid to the thermal sink or modulating a flow of a fluid in
the thermal sink, for example by means of a fan (if the fluid is a gas, such as air),
or a pump (if the fluid is a liquid). Other known control strategies include providing
a cascaded control loop for the expansion valve so as to ensure a fixed amount of
superheat of working fluid entering the compressor by tracking a pressure of the working
fluid at an outlet of the evaporator.
[0003] However, despite various "advanced" control methods having been devised, the non-linear
behaviour of vapour-compression systems remains a challenge. Such non-linear behaviour
may be especially associated with the compressor(s) and/or the valve(s) of the vapour-compression
system. It is desirable to provide a method of controlling a vapour-compression system
which addresses these technical challenges.
[0004] US 8,096,141 B2 describes a control method which regulates an electronic expansion valve of a chiller
to maintain the refrigerant leaving a DX evaporator at a desired or target superheat
that is minimally above saturation. The expansion valve is controlled to convey a
desired mass flow rate, wherein valve adjustments are based on the actual mass flow
rate times a ratio of a desired saturation pressure to the suction pressure of the
chiller. The suction temperature helps determine the desired saturation pressure.
A temperature-related variable is asymmetrically filtered to provide the expansion
valve with appropriate responsiveness depending on whether the chiller is operating
in a superheated range, a saturation range, or in a desired range between the two.
SUMMARY
[0005] According to a first aspect of the present disclosure, there is provided a method
of controlling a vapour-compression system for circulating a working fluid, the vapour-compression
system comprising a compressor, an expansion device and an evaporator configured to
facilitate heat transfer from a thermal source into the working fluid, the method
comprising: determining or receiving a cooling demand, the cooling demand being associated
with a demand to cool the thermal source; determining a preliminary thermofluidic
property objective value based on the cooling demand; determining a final thermofluidic
property objective value based on the preliminary thermofluidic property objective
value and one or more thermofluidic property objective value thresholds, wherein the
final thermofluidic property objective value relates to a target thermofluidic property
of the working fluid at a control location within the vapour-compression system; and
controlling at least one of the compressor and the expansion device based on the final
thermofluidic property objective value.
[0006] The vapour-compression system may further comprise a cooler or a condenser. The final
thermofluidic property objective value may relate to a target temperature of the working
fluid at the control location.
[0007] The final thermofluidic property objective value may relate to a target pressure
of the working fluid at the control location.
[0008] It may be that the method comprises: determining a compressor speed objective value
based on the final thermofluidic property objective value; and controlling a speed
of the compressor based on the compressor speed objective value.
[0009] In addition, or instead, it may be that the method comprises: determining an expansion
device operating parameter objective value based on the final thermofluidic property
objective value; and controlling an operating parameter of the expansion device based
on the expansion device operating parameter objective value. The expansion device
objective value may relate to a degree of opening of the expansion device.
[0010] It may be that the method comprises: monitoring a thermofluidic property of the working
fluid at the control location, and determining the preliminary thermofluidic property
objective value based on both the cooling demand and the monitored thermofluidic property
of the working fluid at the control location.
[0011] It may be that determining the final thermofluidic property objective value includes
applying an integral control aspect and a corrective anti-windup control aspect, the
corrective anti-windup control aspect being based on the monitored thermofluidic property
of the working fluid at the control location.
[0012] The method may comprise determining the cooling demand based on: a temperature setpoint
for the thermal source; and a monitored or predicted temperature of the thermal source.
[0013] It may be that determining the cooling demand is based on a difference between the
temperature setpoint for the thermal source and the monitored or predicted temperature
of the thermal source. The temperature setpoint for the thermal source may be a predetermined
temperature setpoint.
[0014] It may be that the method comprises determining the or each thermofluidic property
objective value threshold based on at least one of: a desired maximum temperature
for working fluid in the vapour-compression system; a critical pressure for working
fluid in the vapour-compression system; a superheat setpoint and/or a subcooling setpoint
for the working fluid in the vapour-compression system; and a monitored temperature
of the working fluid in the vapour-compression system.
[0015] The control location may be: at an outlet of the evaporator; on a suction line of
the vapour-compression system, the suction line extending from the evaporator to the
compressor; at an outlet of the compressor; or on a discharge line of the vapour-compression
system, the discharge line extending from the compressor to a condenser or a cooler
of the vapour-compression system.
[0016] It may be that the control location is at the outlet of the evaporator or on the
suction line of the vapour-compression system, and also that the method comprises:
controlling the expansion device based on the final thermofluidic property objective
value.
[0017] It may be that the control location is at the outlet of the compressor or on the
discharge line of the vapour-compression system, and also that the method comprises:
controlling the compressor based on the final thermofluidic property objective value.
[0018] The method may comprise determining the final thermofluidic property objective value
based on the preliminary thermofluidic property objective value, a lower thermofluidic
property objective value threshold and an upper thermofluidic property objective value
threshold. Determining the final thermofluidic property objective value may include:
setting the final thermofluidic property objective value as being equal to the preliminary
thermofluidic property objective value if the preliminary thermofluidic property objective
value is in a range between the lower thermofluidic property objective value threshold
and the upper thermofluidic property objective value threshold inclusive; setting
the final thermofluidic property objective value as being equal to the lower thermofluidic
property objective value threshold if the preliminary thermofluidic property objective
value is less than the lower thermofluidic property objective value threshold; and
setting the final thermofluidic property objective value as being equal to the upper
thermofluidic property objective value threshold if the preliminary thermofluidic
property objective value is greater than the upper thermofluidic property objective
value threshold.
[0019] It may be that the method comprises: determining an additional final thermofluidic
property objective value, wherein the additional final thermofluidic property objective
value relates to a target thermofluidic property of the working fluid at an additional
control location within the vapour-compression system; and controlling the compressor
and/or the expansion device based on the final thermofluidic property objective value
and the additional final thermofluidic property objective value.
[0020] It may also be that the method comprises: determining a compressor speed objective
value based on both the final thermofluidic property objective value and the additional
final thermofluidic property objective value; and controlling a speed of the compressor
based on the compressor speed objective value.
[0021] Further, it may be that the method comprises: determining an expansion device operating
parameter objective value based on both the final thermofluidic property objective
value and the additional final thermofluidic property objective value; and controlling
an operating parameter of the expansion device based on the expansion device operating
parameter objective value.
[0022] The vapour-compression system may further comprise an additional evaporator configured
to facilitate heat transfer from an additional thermal source into the working fluid.
If so, the method may comprise: determining or receiving an additional cooling demand,
the additional cooling demand being associated with a demand to cool the additional
thermal source; determining an additional preliminary thermofluidic property objective
value based on the additional cooling demand; and determining the additional final
thermofluidic property objective value based on the additional preliminary thermofluidic
property objective value and one or more additional thermofluidic property objective
value thresholds.
[0023] In addition, it may be that the method comprises: determining the preliminary thermofluidic
property objective value based on both the cooling demand and the additional cooling
demand; and determining the additional preliminary thermofluidic property objective
value based on both the additional cooling demand and the cooling demand.
[0024] It may be that the method comprises: determining a preliminary compressor speed objective
value based on the final thermofluidic property objective value; determining a final
compressor speed objective value based the preliminary compressor speed objective
value and one or more compressor speed objective value thresholds; and controlling
a speed of the compressor based on the final compressor speed objective value.
[0025] It may be that the method comprises: determining a preliminary expansion device operating
parameter objective value based on the final thermofluidic property objective value;
determining a final expansion device operating parameter objective value based the
preliminary expansion device operating parameter objective value and one or more expansion
device operating parameter objective value thresholds; and controlling an operating
parameter of the expansion device based on the final expansion device operating parameter
objective value.
[0026] According to a second aspect of the present disclosure, there is provided vapour-compression
system for circulating a working fluid, the vapour-compression system comprising a
compressor, an expansion device, an evaporator configured to facilitate heat transfer
from a thermal source into the working fluid, and a controller configured to carry
out a method in accordance with the first aspect. The vapour-compression system may
further comprise a cooler or a condenser. The or each thermal source may be, or may
include, a battery.
[0027] According to a third aspect of the present disclosure, there is provided a computer
program comprising instructions which, when the program is executed by the controller
of a vapour-compression system in accordance with the second aspect, cause the controller
to carry out a method in accordance with the first aspect.
[0028] According to a fourth aspect of the present disclosure, there is provided a computer-readable
medium having stored thereon a computer program in accordance with the third aspect.
[0029] The skilled person will appreciate that except where mutually exclusive, a feature
described in relation to any one of the above aspects may be applied mutatis mutandis
to any other aspect. Furthermore, except where mutually exclusive any feature described
herein may be applied to any aspect and/or combined with any other feature described
herein.
BREIF DESCRIPTION OF THE DRAWINGS
[0030] Embodiments will now be described by way of example only with reference to the accompanying
drawings, which are purely schematic and not to scale, and in which:
Figure 1 shows a general arrangement of a turbofan engine for an aircraft;
Figure 2 shows an arrangement of a first example vapour-compression system and a block diagram
for a first example controller;
Figure 3 is a schematic diagram showing a block diagram for an outer control logic of the
first example controller;
Figure 4 is a schematic diagram showing a block diagram for a pressure objective limiting
logic of the first example controller;
Figure 5 is an example pressure-enthalpy diagram for transcritical CO2;
Figure 6 is an example pressure-temperature diagram for transcritical CO2;
Figure 7 is an example pressure-enthalpy diagram for subcritical NH3;
Figure 8 is a schematic diagram showing a block diagram for an inner control logic of the
first example controller;
Figure 9 is a schematic diagram showing a block diagram for an actuator state objective limiting
logic of the first example controller;
Figure 10 shows an arrangement of a second example vapour-compression system and a block diagram
for a second example controller;
Figure 11 shows an arrangement of a third example vapour-compression system and a block diagram
for a third example controller; and
Figure 12 is a highly schematic diagram of a machine-readable medium having stored thereon
a computer program which, when executed by a controller, causes the controller to
perform a method of controlling a vapour-compression system in accordance with the
examples of Figures 2 to 11.
DETAILED DESCRIPTION
[0031] A general arrangement of an engine 101 for an aircraft is shown in
Figure 1. The engine 101 is of turbofan configuration, and thus comprises a ducted fan 102
that receives intake air A and generates two pressurised airflows: a bypass flow B
which passes axially through a bypass duct 103 and a core flow C which enters a core
gas turbine.
[0032] The core gas turbine comprises, in axial flow series, a low-pressure compressor 104,
a high-pressure compressor 105, a combustor 106, a high-pressure turbine 107, and
a low-pressure turbine 108.
[0033] In operation, the core flow C is compressed by the low-pressure compressor 104 and
is then directed into the high-pressure compressor 105 where further compression takes
place. The compressed air exhausted from the high-pressure compressor 105 is directed
into the combustor 106 where it is mixed with fuel and the mixture is combusted. The
resultant hot combustion products then expand through, and thereby drive, the high-pressure
turbine 107 and in turn the low-pressure turbine 108 before being exhausted to provide
a small proportion of the overall thrust.
[0034] The high-pressure turbine 107 drives the high-pressure compressor 105 via an interconnecting
shaft. The low-pressure turbine 108 drives the low-pressure compressor 104 via another
interconnecting shaft. Together, the high-pressure compressor 105, high-pressure turbine
107, and associated interconnecting shaft form part of a high-pressure spool of the
engine 101. Similarly, the low-pressure compressor 104, low-pressure turbine 108,
and associated interconnecting shaft form part of a low-pressure spool of the engine
101. Such nomenclature will be familiar to those skilled in the art. Those skilled
in the art will also appreciate that whilst the illustrated engine has two spools,
other gas turbine engines have a different number of spools, e.g., three spools.
[0035] The fan 102 is driven by the low-pressure turbine 108 via a reduction gearbox in
the form of a planetary-configuration epicyclic gearbox 109. Thus, in this configuration,
the low-pressure turbine 108 is connected with a sun gear of the gearbox 109. The
sun gear is meshed with a plurality of planet gears located in a rotating carrier,
which planet gears are in turn meshed with a static ring gear. The rotating carrier
drives the fan 102 via a fan shaft 110. It will be appreciated that in alternative
embodiments a star-configuration epicyclic gearbox (in which the planet carrier is
static and the ring gear rotates and provides the output) may be used instead, and
indeed that the gearbox 109 may be omitted entirely so that the fan 102 is driven
directly by the low-pressure turbine 108.
[0036] It is increasingly desirable to facilitate a greater degree of electrical functionality
on the airframe and on the engine. To this end, the engine 101 of the present embodiment
comprises one or more rotary electric machines, generally capable of operating both
as a motor and as a generator. The number and arrangement of the rotary electric machines
will depend to some extent on the desired functionality. Some embodiments of the engine
101 include a single rotary electric machine 111 driven by the high-pressure spool,
for example by a core-mounted accessory drive 112 of conventional configuration. Such
a configuration facilitates the generation of electrical power for the engine and
the aircraft and the driving of the high-pressure spool to facilitate starting of
the engine in place of an air turbine starter. Other embodiments, including the one
shown in Figure 1, comprise both a first rotary electric machine 111 coupled with
the high-pressure spool and a second rotary electric machine 113 coupled with the
low-pressure spool. In addition to generating electrical power and starting the engine
101, having both first and second rotary machines 111, 113, connected by power electronics,
can facilitate the transfer of mechanical power between the high and lower pressure
spools to improve operability, fuel consumption etc.
[0037] As mentioned above, in Figure 1 the first rotary electric machine 111 is driven by
the high-pressure spool by a core-mounted accessory drive 112 of conventional configuration.
In alternative embodiments, the first electric machine 111 may be mounted coaxially
with the turbomachinery in the engine 101. For example, the first electric machine
111 may be mounted axially in line with the duct between the low- and high-pressure
compressors 104 and 105. In Figure 1, the second electric machine 113 is mounted in
the tail cone 114 of the engine 101 coaxially with the turbomachinery and is coupled
to the low-pressure turbine 108. In alternative embodiments, the second rotary electric
machine 113 may be located axially in line with low-pressure compressor 104, which
may adopt a bladed disc or bladed drum configuration to provide space for the second
rotary electric machine 113. It will of course be appreciated by those skilled in
the art that any other suitable location for the first and (if present) second electric
machines may be adopted.
[0038] The first and second electric machines 111, 113 are connected with power electronics.
Extraction of power from or application of power to the electric machines is performed
by a power electronics module (PEM) 115. In the present embodiment, the PEM 115 is
mounted on the fan case 116 of the engine 101, but it will be appreciated that it
may be mounted elsewhere such as on the core of the gas turbine, or in the vehicle
to which the engine 101 is attached, for example.
[0039] Control of the PEM 115 and of the first and second electric machines 111 and 113
is in the present example performed by an engine electronic controller (EEC) 117.
In the present embodiment the EEC 117 is a full-authority digital engine controller
(FADEC), the configuration of which will be known and understood by those skilled
in the art. It therefore controls all aspects of the engine 101, i.e., both of the
core gas turbine and the first and second electric machines 111 and 113. In this way,
the EEC 117 may holistically respond to both thrust demand and electrical power demand.
[0040] The one or more rotary electric machines 111, 113 and the power electronics 115 may
be configured to output to or receive electric power from one, two or more dc busses.
The dc busses allow for the distribution of electrical power to other engine electrical
loads and to electrical loads on the airframe. The dc busses may further receive electrical
power from, or deliver electrical power to, an energy storage system such as one or
more battery modules or packs.
[0041] Those skilled in the art will appreciate that the gas turbine engine 101 described
above may be regarded as a 'more electric' gas turbine engine because of the increased
role of the electric machines 111, 113 compared with those of conventional gas turbines.
[0042] The gas turbine engine 101 may include one or more thermal sources which benefit
from cooling in use. The one or more thermal sources may include, for example, a battery,
an electrical device, an electric machine, a gearbox, an oil circulation system or
a rotary component of or associated with the gas turbine engine 101. Various types
of thermal management systems may be provided to the gas turbine engine 101 for the
purpose of providing cooling to the one or more thermal sources. In particular, a
vapour-compression circuit or system may be provided to the gas turbine engine for
the purpose of providing cooling to the one or more thermal sources.
[0043] Figure 2 shows a schematic arrangement of a first example vapour-compression system
400 and a block diagram for a first example controller 490. The controller 490 is
generally configured to control the vapour-compression system 400 as described in
further detail herein.
[0044] The first example vapour-compression system 400 is generally configured for circulating
a working fluid. The working fluid may include, for instance, a refrigerant. The refrigerant
may be, or include, carbon-dioxide and/or ammonia as referred to in the following
description for exemplary purposes. However, other refrigerants may be used within
the vapour-compression system 400. The first example vapour-compression system 400
comprises a compressor 402, a condenser/cooler 404, an expansion device 406, a primary
evaporator 408A and a secondary evaporator 408B. The primary evaporator 408A may be
simply referred to as the evaporator 408A and the secondary evaporator 408B may be
referred to as the additional evaporator 408B.
[0045] A discharge line 412 extends from the compressor 402 to the condenser/cooler 404.
A pre-expansion line 414 (which may sometimes be referred to as a liquid line 414)
extends from the condenser/cooler 404 to the expansion device 406, whereas a post-expansion
line 416 (which may sometimes be referred to as a distributor line 416) extends from
the expansion device 406 to the primary evaporator 408A. A suction line 418 extends
from the primary evaporator 408A, through the secondary evaporator 408B, to the compressor
402. Accordingly, the first and secondary evaporators 408A, 408B are fluidically connected
in series. In other examples in accordance with the present disclosure, the first
and secondary evaporators 408A, 408B are fluidically connected in parallel. The expansion
device 406 may be, or comprise, a throttle valve or a turbine (e.g., a centrifugal-type
turbine).
[0046] The first example vapour-compression system 400 also comprises an internal heat exchanger
409 (which may be referred to as an economiser heat exchanger 409). The pre-expansion
line 414 extends through a side of the internal heat exchanger 409 and the suction
line 418 extends through another side of the internal heat exchanger 409. The internal
heat exchanger 409 is configured to facilitate heat exchange between working fluid
in the pre-expansion line 414 and working fluid in the suction line 418 to provide
an increased efficiency to the vapour-compression system 400, for reasons which will
be generally similar to those skilled in the art. It will, however, be appreciated
that in other example vapour-compression systems in accordance with the present disclosure,
an internal heat exchanger may not be present or included.
[0047] The condenser/cooler 404 is generally configured to facilitate heat exchange between
working fluid passing therethrough and a thermal sink. In particular, the condenser/cooler
404 is configured to facilitate heat transfer from the working fluid passing therethrough
into the thermal sink. In the specific example of Figure 2, the thermal sink is a
process fluid (e.g., a sink fluid) provided to the condenser/cooler 404 by a sink
fluid passageway 403 which forms part of a sink fluid loop (not shown). Accordingly,
in this particular example, the condenser/cooler 404 is configured to facilitate heat
exchange between a pair of interfacing fluids. However, it will be appreciated that
the thermal sink may not be, or may not include, a fluid. That is, the thermal sink
may be, or may include, a solid structure. For ease of explanation, the sink fluid
passageway 403 and the thermal sink may be referred to using the same reference sign
herein.
[0048] Each evaporator 408A, 408B is generally configured to facilitate heat exchange between
working fluid passing therethrough and respective thermal source. In particular, each
evaporator 408A, 408B is configured to facilitate heat transfer into the working fluid
passing therethrough from the respective thermal source. In the specific example of
Figure 2, each thermal source is a process fluid (e.g., a source fluid) provided to
the evaporators 408A, 408B for co-current flow with the working fluid of the vapour-compression
system 400 by respective source fluid passageways 407A, 407B forming parts of respective
source fluid loops (not shown). In other examples, the process fluid may be provided
to the evaporators 408A, 408B for counter-current flow with the working fluid of the
vapour-compression system 400 by the respective source fluid passageways 407A, 407B.
Consequently, in this particular example, the evaporators 408A, 408B are configured
to facilitate heat exchange between a pair of interfacing fluids. Nevertheless, it
will be appreciated that the or each thermal source may not be, or may not include,
a fluid. Namely, the or each thermal source may be, or may include, a solid structure.
In particular, the or each thermal source may be, or may include, a battery or an
oil circulation system associated with a gas turbine engine and/or an airframe to
which a gas turbine engine is provided. For ease of explanation, the source fluid
passageways 407A, 407B and the thermal sources may be referred to using the same reference
signs herein. The thermal source 407A provided to the primary evaporator 408A may
be referred to as the primary thermal source 407A, and the thermal source 407B provided
to the secondary evaporator 48B may be referred to as the secondary thermal source
407B.
[0049] For the purposes of the following description, a plurality of monitoring locations
on the vapour-compression system 400 are now defined. A first system monitoring location
1 is on the suction line 418 between the internal heat exchanger 409 and the compressor
402, a second system monitoring location 2 is on the discharge line 412, a third system
monitoring location 3 is on the pre-expansion line 414 between the condenser/cooler
404 and the internal heat exchanger 409, a fourth system monitoring location 4 is
on the pre-expansion line 414 between the internal heat exchanger 409 and the expansion
device 406, a fifth system monitoring location 5 is on the post-expansion line 416
between the expansion device 406 and the primary evaporator 408A, an auxiliary fifth
system monitoring location 5b is on the suction line 418 between the primary evaporator
408A and the secondary evaporator 408B, and a sixth system monitoring location 6 is
on the suction line between the secondary evaporator 408B and the internal heat exchanger
409.
[0050] Also for the purposes of the following description, a plurality of monitoring locations
on the thermal sources 407A, 407B are defined. A primary source monitoring location
A is located on the primary source fluid passageway 407A downstream of, and proximal
to, a source-side outlet of the primary evaporator 408A and a secondary source monitoring
location B is located on the secondary source fluid passageway 408A downstream of,
and proximal to, a source-side outlet of the secondary evaporator 408B.
[0051] The controller 490 is configured to control both the compressor 402 and the expansion
device 406 in accordance with the methodology (i.e., the method) described herein
with reference to Figures 2 to 9. More particularly, the controller 490 is configured
to control a flow rate (e.g., a mass-flow rate) of working fluid through the vapour-compression
system 400 by controlling an operating parameter of the compressor 402. In the example
of Figure 2, the operating parameter of the compressor 402 is a speed (i.e., a rotational
speed) of the compressor 402. Moreover, the controller 490 is configured to control
a pressure differential between working fluid within the vapour-compression system
400 on either side of the expansion device 406 (e.g., a pressure difference between
working fluid at the fourth system monitoring location 4 and at the fifth system monitoring
location 5) by controlling an operating parameter of the expansion device 406. In
the example of Figure 2, the operating parameter of the expansion device 406 is a
degree of opening of the expansion device 406. In other examples, the operating parameter
of the expansion device 406 may relate to a position of a variable geometry feature
of the expansion device 406 (e.g., if the expansion device is a turbine). The compressor
402 and the expansion device 406 are therefore two separate actuators operable by
the controller 490 to control operation of the vapour-compression system 400.
[0052] In the example of Figure 2, the controller 490 comprises an outer control logic 300,
a pressure limiting logic 200, an inner control logic 800 and an actuator operating
parameter objective limiting logic 900. In various examples in accordance with the
present disclosure, the controller 490 does not comprise the actuator operating parameter
objective limiting logic 900. The controller 490 further comprises a signal processing
module 495. The controller 490 may be understood as comprising two cascaded control
loops (i.e., an outer control loop and an inner control loop). The inner control loop
is implemented by the inner control logic 800, while the outer control loop is controlled
by the outer control logic 300. Further, and as will be described in further detail
below, the pressure limiting logic 200 enforces various thermofluidic constraints
by selectively limiting pressure objective values provided to the inner control logic
800.
[0053] In this example, the controller 490 is configured to receive system input signals
from respective system sensing arrangements at the second system monitoring location
2, at the fifth system monitoring location 5 and at the sixth system monitoring location
6. The controller 490 is also configured to receive source input signals from respective
source sensing arrangements at the primary source monitoring location A and at the
secondary source monitoring location B. At least some of the input signals are received
and processed by the signal processing module 495 prior to being received by other
aspects of the controller 490, as described in further detail below. In other examples
in accordance with the present disclosure, the controller 490 is configured to receive
such system input signals from system sensing arrangement at any one, combination,
or all of the system monitoring locations 1-6.
[0054] Each system input signal comprises information relating to the pressure of the working
fluid at the respective monitoring location 2, 6 and/or the temperature of the working
fluid at the respective monitoring location 2, 5, 6. In the example of Figure 2, some
of the system input signals are received by the signal processing module 495 in the
form of a two-element array, with each element corresponding to either the pressure
of the working fluid at the monitoring location 2, 6 or the temperature of the working
fluid at the monitoring location 2, 6. That is, the signal processing module 495 receives
a first system input signal (
P2, T2) relating to both the temperature
T2 at the second system monitoring location 2 and the pressure
P2 at the second system monitoring location 2 as well as a second system input signal
(
P6, T6) relating to both the temperature
T6 at the sixth system monitoring location 6 and the pressure
P6 at the sixth system monitoring location 6. A third system input signal (
T5) is otherwise received by the controller 490.
[0055] Each source input signal comprises information relating to the temperature of the
respective source 407A, 407B. In the example of Figure 2, each source input signal
is received by the signal processing module 495 in the form of separate values, with
each value corresponding to the temperature
Ta at the primary source monitoring location A and the temperature
Tb at the secondary source monitoring location B, respectively.
[0056] In the example of Figure 2, the signal processing module 495 receives and processes
each of the input signals as follows. The first system input signal
P2, T2 is demultiplexed (e.g., split) into the temperature
T2 and the pressure
P2 at the second system monitoring location 2. Similarly, the second system input signal
P6, T6 is demultiplexed (e.g., split) into the temperature
T6 and the pressure
P6 at the sixth system monitoring location 6. The system temperatures
T2 and
T6 are multiplexed (e.g., concatenated) to form a two-element system temperature array
T2, T6 comprising a first system temperature
T2 and a second system temperature
T6. The system pressures
P2 and
P6 are multiplexed (e.g., concatenated) to form a two-element system pressure array
P2, P6. The source temperatures
Ta and
Tb, as received in the source input signals, are multiplexed to form a two-element source
temperature array
Ta, Tb.
[0057] In the example of Figure 2, the outer control logic 300 is configured to receive
the source temperature array
Ta, Tb from the signal processing module 495 as an input and to provide a preliminary pressure
objective value array
P2|r, P6|r as an output to the pressure limiting logic 200. The preliminary pressure objective
value array
P2|r, P6|r is a two-element array comprising a first preliminary pressure objective value
P2|r for working fluid at the second system monitoring location 2 (e.g., a preliminary
pressure objective value
P2|r) and a second preliminary pressure objective value
P6|r for working fluid at the sixth system monitoring location 6 (e.g., an additional
preliminary pressure objective value
P6|r).
[0058] In turn, the pressure limiting logic 200 is configured to receive the system temperature
array
T2, T6, the third system input signal/temperature
T5, the preliminary pressure objective value array
P2|r, P6|r and the system pressure array
P2, P6 from the signal processing module 495 as inputs and to provide a final pressure objective
value array
P2|l, P6|l as an output to the inner control logic 800. The final pressure objective value array
P2|l, P6|l is a two-element array comprising a first final pressure objective value
P2|l for working fluid at the second system monitoring location 2 (e.g., a final pressure
objective value
P2|l) and a second final pressure objective value
P6|l for working fluid at the sixth system monitoring location 6 (e.g., an additional
final pressure objective value
P6|l). The first final pressure objective value
P2|l relates to a target pressure of working fluid at the second system monitoring location
2, whereas the second final pressure objective value
P6|l relates to a target pressure of working fluid at the sixth system monitoring location
6. The second system monitoring location 2 may therefore be referred to as a first
control location 2 (e.g., a control location 2) and the sixth system monitoring location
6 may also be referred to as a second control location 6 (e.g., an addition control
location 6). More generally, the first control location 2 may be anywhere on the discharge
line 412 or at an outlet of the compressor 402 and the second control location 6 may
be anywhere on the suction line 418 or at an outlet of the secondary evaporator 408B.
Preferably, the second control location 6 is between the secondary evaporator 408B
and the internal heat exchanger 409. As is described in further detail below, each
final pressure objective value may be the same as (e.g., equal to) or different to
(e.g., greater than or less than) the corresponding preliminary pressure objective
value.
[0059] Further, the inner control logic 800 is configured to receive the system pressure
array
P2, P6 and the final pressure objective value array
P2|l, P6|l as inputs and to provide a preliminary actuator operating parameter objective array
ωc|r,
uv|r, as an output to the actuator operating parameter objective limiting logic 900. The
preliminary actuator operating parameter objective array
ωc|r,
uv|r, is a two-element array comprising a preliminary compressor operating parameter objective
value
ωc|r for the compressor 402 (e.g., a preliminary actuator operating parameter objective
value
ω c|r) and a preliminary expansion device operating parameter objective value
u v|r for the expansion device 406 (e.g., an additional preliminary actuator operating
parameter objective value
u v|r).
[0060] Finally, the actuator operating parameter objective limiting logic 900 is configured
to receive the preliminary actuator operating parameter objective array
ω c|r,
uv|r as an input and to provide a final actuator operating parameter objective array
ω c|l, u v|l as an output to the actuators 402, 406 of the vapour-compression system 400 (that
is, to the compressor 402 and the expansion device 406). The final actuator operating
parameter objective array
ω c|l, u v|l is a two-element array comprising a final compressor operating parameter objective
value
ω c|l for the compressor 402 (e.g., a final actuator operating parameter objective value
ω c|r) and a final expansion device operating parameter objective value
u v|l for the expansion device 406 (e.g., an additional final actuator operating parameter
objective value
u v|r).
[0061] The outer control logic 300 is also configured to receive the system pressure array
P2, P6 from the signal processing module 495 as a further input, whereas the inner control
logic 800 is also configured to receive the final actuator operating parameter objective
array
ω c|l,
u v|l from the actuator operating parameter objective limiting logic 900 as a further input.
[0062] The final actuator operating parameter objective array
ω c|l,
u v|l is then demultiplexed (e.g., split) into the final compressor operating parameter
objective value
ω c|l and the final expansion device operating parameter objective value
u v|l. The compressor 402 is then controlled in accordance with the final compressor operating
parameter objective value
ω c|l by a suitable compressor control scheme (represented by the dashed line extending
from the controller 490 to the compressor 402 in Figure 2), for example to maintain
the speed of the compressor 402 at, or within a tolerance range of, the final compressor
operating parameter objective value
ω c|l. Accordingly, the final compressor operating parameter objective value
ω c|l may be referred to as a compressor speed objective value
ω c|l. In a similar way, the expansion device 406 is controlled in accordance with the
final expansion device operating parameter objective value
u v|l by a suitable expansion device control scheme (represented by the dashed line extending
from the controller 490 to the expansion device 406 in Figure 2), for example to maintain
the degree of opening of the expansion device 406 at, or within a tolerance range
of, the final expansion device operating parameter objective value
u v|l.
[0063] The combined action of the outer control logic 300 and pressure limiting logic 200
can be conceived of as providing a non-linear transformation from the temperature
domain to the pressure domain and providing objective limitation in the pressure domain.
The further action(s) of the inner control logic 800 are then carried out in the pressure
domain (e.g., with respect to pressure values). Nevertheless, this disclosure envisages
that one or more, or all, of the control actions described herein as being carried
out in the pressure domain could be carried out in the temperature domain. If so,
the pressure limiting logic 200 may be replaced by a temperature limiting logic, with
appropriate temperature constraints being applied by the temperature limiting logic
using the functions described below with reference to the pressure limiting logic
200. In addition, if so, the final thermofluidic property objective value(s) may relate
to a target temperature of the working fluid at the control location(s). However,
superior performance of the controller 490 may be enabled by carrying out control
actions in the pressure domain, because this variable typically changes faster than
temperature and/or because suitable temperature sensors for the purposes described
may typically have longer rise times than suitable pressure sensors suitable for these
purposes. This is facilitated by use of the two cascaded control loops (i.e., the
outer control loop and the inner control loop).
[0064] Figure 3 is a schematic diagram showing a detailed block diagram of the outer control logic
300. The outer control logic 300 includes determining, at block 310, a cooling demand
array
ΔTa, ΔTb. In this example, the cooling demand array
ΔTa, ΔTb is determined as being a difference between the source temperature array
Ta, Tb array and a setpoint temperature array
Ta|s, Tb|s. Consequently, the cooling demand array
ΔTa, ΔTb may be referred to as a temperature error array
ΔTa, ΔTb.
[0065] The setpoint temperature array
Ta|s, Tb|s is a two-element array comprising a temperature setpoint value
Ta|s for the primary thermal source 407A (e.g., a first temperature setpoint value
Ta|s) and a temperature setpoint value
Ta|s for the secondary thermal source 407B (e.g., a first temperature setpoint value
Tb|s). Accordingly, the cooling demand array
ΔTa, ΔTb is a two-element array comprising a temperature error value
ΔTa associated with the primary thermal source 407A (e.g., a primary cooling demand
ΔTa or, more simply, a cooling demand
ΔTa) and a temperature error value
ΔTb associated with the secondary thermal source 407B (e.g., a secondary cooling demand
ΔTb or, more simply, an additional cooling demand
ΔTb). Each cooling demand
ΔTa and
ΔTb is associated with a demand to provide cooling to (e.g., to cool) the corresponding
thermal source 407A, 408B. In this example, each cooling demand
ΔTa and
ΔTb is determined based on (a difference between) the corresponding temperature setpoint
Ta|s, Tb|s and the corresponding monitored temperature
Ta, Tb of the thermal source 407A, 407B. In other examples, the outer control logic 300
may determine the cooling demand(s) by receiving the cooling demand(s) from an external
data processing apparatus and/or a dedicated sensing system provided to the thermal
source(s) 407A, 408B. The setpoint temperatures
Ta|s and
Tb|s may be predetermined values stored within a memory of the controller 490 or may be
received from an external data processing apparatus, such as a user-interface or a
machine-interface to the controller 490 and/or the vapour-compression system 400.
In the latter case, the setpoint temperatures
Ta|s and
Tb|s may vary in use.
[0066] The outer control logic 300 includes a proportional-integral (PI) action, represented
by blocks 320, 330, 340 and 350, for determining the preliminary pressure objective
value array
P2|r, P6|r. The PI action is carried out with the intention of reducing each temperature error
value (ideally to zero). The outer control logic 300 also includes an anti-windup
action for correcting possible wind-up associated with the integral aspect of the
PI action (e.g., a corrective anti-windup control aspect), which is implemented by
application of a backstepping gain as described in further detail below. That is,
including the integral aspect in the PI action may, in turn, cause problems when the
setpoint temperature(s)
Ta|s, Tb|s are effectively unattainable and/or due to the action of the pressure limiting logic
200 described below. In this case, the temperature error array
ΔTa, ΔTb will keep accumulating, causing a so-called windup effect. Therefore, an anti-windup
action is also included, synthesized using a backstepping gain
Kt b as explained in further detail below.
[0067] To capture possible wind-up associated with any unattainability of the setpoint temperature(s)
Ta|s, Tb|s and the action of the pressure limiting control logic 200 (as well as the action(s)
of the inner control logic 800 and the actuator operating parameter objective limiting
logic 900), the backstepping gain
Kt b is advantageously applied in respect of the system pressure array
P2, P6 (in the example of Figure 3) such that the preliminary pressure objective value array
P2|r, P6|r is determined based on both the cooling demand array
ΔTa, ΔTb and the system pressure array
P2, P6. In other words, this approach covers not only a scenario in which pressure objective
values are dynamically limited by the pressure limiting logic 200, but also when saturation
occurs in the inner control logic 800 and/or in the actuator operating parameter objective
limiting logic 900, as this saturation will be reflected on measured system pressure
array
P2, P6 (i.e., the pressure(s) ultimately achieved in the working fluid circulated by the
vapour-compression system 400). This approach contrasts with previously-considered
(e.g., prior art) anti-windup approaches which rely on complex synthesis methods involving
plant identification and dynamics inversion.
[0068] The application of a proportional gain
Ktp to the temperature error array
ΔTa, ΔTb to produce a proportional preliminary pressure term array
P2|r p, P6|r p is represented by block 320. The preliminary pressure objective value array
P2|r, P6|r is subtracted from the system pressure array
P2, P6 at block 360 to yield a backstepping pressure array
P2b,
P6b. In turn, the application of a backstepping gain
Ktb to the backstepping pressure array
P2b, P6b to produce a backstepping temperature array
Ta b, Tb b is represented by block 370. The temperature error array
ΔTa, ΔTb and the backstepping temperature array
Ta b, Tb b are added at block 380 to produce a backstepped temperature error array
ΔTa b, ΔTb b. The time-integration of the backstepped temperature error array
ΔTa b, ΔTb b and the application of an integral gain
Kti to a time-integral temperature error array to produce an integral preliminary pressure
term array
P2|r i,
P6|r i is represented by blocks 330 and 340, respectively. The proportional preliminary
pressure term array
P2|r p, P6|r p and the integral preliminary pressure term array
P2|r i, P6|r i are then added, as represented by block 350, to produce the preliminary pressure
objective value array
P2|r, P6|r. As a result, the preliminary pressure objective value array
P2|r, P6|r is determined based on both the cooling demand array
ΔTa, ΔTb and the monitored pressure
P2, P6 of the working fluid at the control locations 2, 6. Each of the gains
Ktp, Ktb, Kti described above are in the form of 2 by 2 matrices. Application of the gains
Ktp, Kt b, Kti at blocks 320, 340 and 370 is performed using matrix multiplication of the relevant
arrays and gain matrices.
[0069] It follows that each of the first preliminary pressure objective value
P2|r and the second preliminary pressure objective value
P6|r are determined based on both the primary cooling demand
ΔTa and the second cooling demand
ΔTb. In other words, the first preliminary pressure objective value
P2|r is influenced by both the primary cooling demand
ΔTa and the second cooling demand
ΔTb and the second preliminary pressure objective value
P6|r is influenced by both the primary cooling demand
ΔTa and the second cooling demand
ΔTb. For this reason, the outer control logic 300 described with respect to Figures 2
and 3 may be referred to as a multivariable outer control logic 300 or a multiple-input
multiple-output (MIMO) outer control logic 300.
[0070] Figure 4 is a schematic diagram showing a detailed block diagram of the pressure limiting
control logic 200. The pressure limiting control logic 200 is generally adapted to
enforce safe and effective thermofluidic constraints for working fluid circulated
by the vapour-compression system 400. There are various thermofluidic constraints
that may be imposed (e.g., enforced) in respect of the working fluid in the vapour-compression
system 400. The aim of enforcing some of these thermofluidic constraints is to ensure
safe operation of specific components of the vapour-compression system 400, while
the aim of enforcing some of these thermofluidic constraints is to achieve a particular
operational regime for the working fluid at a given locations within the vapour-compression
system 400.
[0071] In a previously-considered vapour-compression system, such thermofluidic constraints
were considered during the design phase by appropriate sizing of components. Some
safety-critical constraints were then enforced by the use of physical elements like
liquid receivers.
[0072] In future aerospace applications, and electric vehicles in general, the cooling demand(s)
associated with the thermal source(s) are likely to vary dynamically in a relatively
wide range. In addition, the broader operating conditions, especially in the case
of aerospace applications, will also change in a much wider range due to the changes
in the environment as altitude and speed vary. All these dynamic changes in respect
of the thermal source(s) and the sink(s) make it highly beneficial for the controller
to incorporate some functionality to enforce compliance with relevant thermofluidic
constraints.
[0073] To address this challenge, other previously-considered control methodologies attempted
to make use of model predictive control techniques. However, such techniques often
require a deep understanding of the theoretical framework underpinning the vapour-compression
system in order to deploy the control logic, as well as an accurate model of the system
to make appropriate predictions (in addition to providing the vapour-compression system
with controller(s) with powerful enough processors to run optimisation in real-time).
[0074] In contrast, the implementation proposed in the present disclosure simplifies the
approach by explicitly defining thermofluidic limits (e.g., in the pressure domain)
and tuning the two cascaded control loops accordingly. Moreover, the implementation
proposed in the present disclosure allows the controller 490 to be readily adapted
for use with a range of different types of working fluids (e.g., refrigerants) to
be circulated by the vapour-compression system 400 using only minor adaptations to
the pressure limiting logic 200 (e.g., by modifying the thermofluidic constraints
to be enforced by the pressure limiting logic 200 according to the characteristics
of the working fluid to be used).
[0075] Exemplary thermofluidic constraints employed in the present disclosure relate to
any of the following:
- (i) compressor protection: it is preferable that the working fluid is in an entirely
gaseous form before entering the compressor 402. A thermofluidic constraint on this
basis may be imposed as a superheat condition at the outlet of the evaporators 408A,
408B (i.e., at the second control location 6). Namely, the working fluid should be
at a temperature greater than (e.g., a (predetermined) specified amount greater than)
the saturation temperature of the working fluid at the second control location 6,
as defined according to the current operating pressure of the working fluid at the
second control location 6.
- (ii) temperature protection: some working fluids may start to degrade if and when
a certain temperature threshold is exceeded (e.g., a maximum working fluid temperature
threshold). Further, internal components of the compressor 402 may suffer from reduced
performance and/or be liable to damage when the working fluid passing through the
compressor 402 is at a high temperature. It is thus desirable to impose a constraint
on the highest temperature of the system, which is on the discharge line 412 (e.g.,
at the second monitoring location 2).
- (iii) operating regime: it might be also desired to operate the working fluid charged
in the vapour-compression system 400 in a trans-critical or sub-critical regime, depending
on the working fluid (e.g., the refrigerant) being used. If a trans-critical regime
is desired, the pressure of working fluid on the "high-pressure" side of the vapour-compression
system 400 (which may be referred to as the cooling pressure of the condensation pressure)
should be always above the critical pressure of the fluid, whereas for a sub-critical
regime, the condensation pressure should always be below the critical pressure.
- (iv) expansion device protection: for a sub-critical regime, it might also be preferable
to have the fluid as fully liquid before entering the expansion device, and thus a
certain amount of subcooling is usually required. This may be enforced by ensuring
that the temperature of working fluid in the pre-expansion line 414 (e.g., at the
third monitoring location 3) is below the saturation temperature of the working fluid
at the condensation pressure.
- (v) thermal runaway protection: when a certain mass flow of working fluid circulating
in the vapour-compression system 400 is exceeded, the vapour-compression system 400
may be at risk of spiralling into a thermal runaway (i.e., increasing the temperature
of the refrigerant when increasing the mass flow). This is associated with non-linear
behaviour that results from the decrease in heat rejection in the condenser/cooler
404 when mass flow is increased. One possible way of ensuring that this risk is mitigated
is by limiting the amount of superheat in the primary evaporator 408A (e.g., not allowing
the primary evaporator 408A to have the fluid inside as full vapour). This can be
enforced by imposing a maximum superheat constraint of working fluid in the post-expansion
line 416 (e.g., at the fifth monitoring location 5).
- (vi) minimum performance: the vapour-compression system may be most efficient when
the working fluid inside the evaporator(s) 408A, 408B is in mixed phase and becomes
vapour at the outlet of the secondary evaporator 408B. However, for safety reasons,
it may be desired to have a minimum amount of superheat of the working fluid in this
monitoring location (e.g., at the sixth monitoring location 6). In order to not deviate
too significantly from optimum performance, it might also be desirable to define a
maximum superheat amount for the working fluid, which is enforced by not allowing
the temperature of working fluid at the outlet of the evaporators 408A, 408B (e.g.,
on the suction line 418 at the sixth monitoring location 6) to be above the saturation
temperature plus a predetermined maximum difference.
[0076] The expression and enforcement of all the thermofluidic constraints into the pressure
domain, as in preferred examples of the present disclosure, is possible given the
fact that the saturation temperature increases monotonically with the saturation pressure,
even if this increase is non-linear. This allows to translate various temperature
inequality requirements into pressure constraints, adding these to the constraints
defined explicitly in pressure.
[0077] To illustrate this point,
Figure 5 shows a pressure-enthalpy diagram for an example idealised transcritical regime carbon
dioxide (CO
2) working fluid vapour-compression system having an architecture which corresponds
to that of the vapour-compression system 400 shown by Figure 2 (i.e., having two evaporators
408A, 408B in series, an internal heat exchanger 409 and the monitoring locations
1-6).
[0078] Figure 5 shows some of the exemplary thermofluidic constraints: the saturation line
is a minimum energy condition for the sixth monitoring location/second control location
6, and a maximum energy conditions for the fifth monitoring location 5. The maximum
temperature line is a maximum energy condition for the second monitoring location
2, and the critical pressure is a minimum pressure for each of the second, third and
fourth monitoring locations 2, 3 and 4.
[0079] Each of these thermofluidic constraints can be formulated in either the temperature
or the pressure domain. This can be clearly seen in
Figure 6, where the same cycle from Figure 5 is represented in the pressure-temperature plane
(the specific enthalpy isolines are plotted here without value for ease of understanding).
[0080] It can be seen that the saturation line (separating liquid and vapour areas) is a
monotonic line in the pressure-temperature space, allowing to project a temperature
restriction into a pressure restriction when this restriction refers to the saturation
line (this is, all superheat and subcooling conditions can be formulated as pressure
limits). Regarding the maximum temperature (e.g., the maximum allowed temperature
or the maximum desired temperature), it can also be formulated as a limit in pressure
if one looks at the same specific-enthalpy lines (for each enthalpy isoline there
is a maximum pressure, when this isoline crosses the maximum temperature line). Following
this reasoning, a strictly positive and monotonic function
Tsat(
P) can be defined as the temperature in the saturation line for pressure that range
between the minimum pressure of the working fluid and the critical pressure of the
working fluid. In the same manner, a strictly positive and monotonic function
Psat(
T) can be defined as the pressure in the saturation line for a temperature ranging
between the minimum temperature of the working fluid and the critical temperature
of the working fluid.
[0081] Further, it can be said that the two functions are inverses to each other. In other
words,
P = Psat(
Tsat(
P)) and
T = Tsat(
Psat(
T))
. Using these two functions, all of the thermofluidic constraints related to the saturation
line can be easily translated into pressure as follows.
[0082] Starting with a minimum and/or a maximum superheat amount at a monitoring location
i. A superheat amount
shi can be defined as a difference between the temperature
Ti of working fluid at the relevant monitoring location and the saturation temperature
at the current pressure
Tsat(
Pi), per Equation
Error! Reference source not found.. 
[0083] Defining a minimum desired amount of superheat

at a particular monitoring location is essentially equivalent to saying that the
temperature
Ti of the working fluid at the relevant monitoring location should be at least at the
saturation temperature
Tsat(
Pi) plus a predetermined minimum superheat amount/superheat setpoint

, per Equation
Error! Reference source not found. below.

Moving the superheat setpoint

to the left side, and applying the pressure function defined previously to both sides
of the remaining inequality (which can be done without changing the sign of the inequality
due to the properties defined before), Equation
Error! Reference source not found. may be rewritten as Equation
Error! Reference source not found.

where the superheat condition has been translated into a maximum pressure condition
at monitoring location
Pi which is determined dynamically by the current temperature
Ti and the superheat requirement
.
[0084] In a similar way to the previously-described constraint, a maximum superheat (

) requirement at a given monitoring location can be translated into a minimum pressure
limit at the said monitoring location (that is, turning Equation
Error! Reference source not found. into Equation
Error! Reference source not found. as shown below).

[0085] Combining Equations
Error! Reference source not found. and
Error! Reference source not found. yields Equation
Error! Reference source not found., which succinctly defines two limits that can be imposed on the pressure at the relevant
monitoring location i in order to guarantee that the superheat amount lies within
an appropriate range.

[0086] Like the above-described approach for expressing the superheat-related thermofluidic
constraints as pressure limits, subcooling-related thermofluidic constraints can be
similarly enforced at any of the monitoring locations 1-6 by translating them into
the pressure domain. Subcooling may be defined as a difference between the current
temperature of working fluid at the relevant monitoring location and the saturation
temperature at the same relevant pressure, per Equation
Error! Reference source not found.. 
[0087] It can be noted that, according to the definitions given in Equations
Error! Reference source not found. and
Error! Reference source not found., subcooling may be defined as a negative superheat such that
sci = -
shi. Therefore, following the same reasoning as that followed above for the superheat,
and knowing the equivalence with subcooling, Equation (1) may be arrived at. Equation
(8) defines the limits for the pressure of working fluid at the monitoring location
i if subcooling conditions are to be imposed thereat (e.g., a minimum subcooling amount/subcooling
setpoint).

[0088] Restrictions for the maximum working fluid temperature can also be defined in the
pressure domain by using several transformations. One specific methodology described
herein includes first obtaining the specific enthalpy of the monitoring location to
be limited using the function

, which can only be defined in single-phase regions (this function can be seen in
Figure 6, where the isolines are the values for the specific enthalpy for each combination
of temperature and pressure in single-phase stages).
[0089] An additional function that provides the pressure value equivalent to the maximum
temperature for a given specific enthalpy is also defined. That is, a function is
defined that describes the maximum temperature isotherm
PTmax(
h) (as seen in Figure 5 for the 420K isotherm).
[0090] With these two functions defined, it can then be said that the pressure of working
fluid at the monitoring location to be constrained should be below the pressure of
the isotherm representing the maximum temperature for the current specific enthalpy,
as per Equation (2) below.

[0091] The same principle can be applied to a minimum temperature for the working fluid
by simply defining a pressure function defining the minimum temperature isotherm
PTmin (h) as given by Equation (10). This is possible due to the monotonic relationship between
pressure and specific enthalpy for a constant temperature (see Figure 5), regardless
of the phase of the working fluid in a single-phase regime.

[0092] On the other hand, if the relevant monitoring location is at a point in the vapour-compression
system 400 where the working fluid is dual-phase, the translation is even simpler,
as the function
Psat(
T) defined for the superheat above can be used to constraint the pressure between the
pressures equivalent to the minimum and maximum temperatures, as per Equation (4)
below.

[0093] A further type of thermofluidic constraint that may be imposed by the pressure limiting
logic 200 is one which enforces a specific operating regime of the vapour-compression
system 400, such as enforcing a subcritical regime (all pressures below the critical
pressure value), a trans-critical regime (evaporation stages below the critical pressure,
and cooling monitoring locations in above the critical pressure), or supercritical
regimes (all pressures above the critical pressure value). Since each of these constraints
are defined directly in the pressure domain, it is straight-forward to include them
in a set of pressure limitations to be applied by the pressure limiting logic 200
by simply imposing the minimum or maximum pressure constraints at the relevant monitoring
locations.
[0094] By way of example, if a transcritical regime is to be employed, pressure constraints
may be added in accordance with Equations (12) and (13) below, which define a subcritical
constraint at the first monitoring location 1 (on the suction line 418 and/or at the
compressor inlet), and a supercritical constraint at the second monitoring location
2 (on the discharge line 412 and/or as the compressor outlet).

[0095] By way of another example, if a subcritical regime is to be employed, pressure constraints
may be added in accordance with Equations (14) and (15) below, which define a subcritical
constraint at the first monitoring location 1 (on the suction line 418 and/or at the
compressor inlet), and a subcritical constraint at the second monitoring location
2 (on the discharge line 412 and/or as the compressor outlet).

[0096] For completeness,
Figure 7 shows a pressure-enthalpy diagram for an example idealised subcritical regime ammonia
(NH
3) working fluid vapour-compression system having an architecture which corresponds
to that of the vapour-compression system 400 shown by Figure 2 (i.e., having two evaporators
408A, 408B in series, an internal heat exchanger 409 and the monitoring locations
1-6).
[0097] These functions, relationships and equivalences can be used to enforce all the thermofluidic
constraints outlined above, providing a dynamic definition of a maximum and minimum
value for both the evaporation pressure (that is, the pressure of the working fluid
in the "low-pressure" side of the system 400 at the sixth monitoring location 6) and
the condensation/cooling pressure (that is, the pressure of the working fluid in the
"high-pressure" side of the system 400 at the second monitoring location 2). For instance,
the above-described thermofluidic constraints can be enforced by defining them in
the pressure domain for the two system pressures (e.g., the evaporation pressure at
the second control location 6 and the condensation pressure at the first control location
2), as outlined in
[0098] Table 1 for a transcritical working fluid regime (e.g., using carbon dioxide as at
least part of the working fluid) and as outlined in Table 2 for a subcritical regime
(e.g., using ammonia as at least part of the working fluid).
[0099] Means of translating all of the desired thermofluidic constraints into limits for
the two working pressures in the vapour-compression system 400 (e.g., the evaporation
pressure at the second control location 6 and the condensation pressure at the first
control location 2) of the vapour-compression system 400 are therefore provided. In
use, these limits are enforced by the pressure limiting logic 200 so as to trim the
preliminary pressure objective values
P2|r, P6|r outputted by the outer control logic 300 before these are subsequently provided to
the inner control logic 800 as final pressure objective values
P2|l, P6|l.
[0100] Returning now to Figure 4, the pressure limiting logic 200 is shown as comprising
a first comparator 210 and a second comparator 220. The first comparator 210 receives
the first preliminary pressure objective value
P2|r as an input and provides the first final pressure objective value
P2|l as an output. In a similar way, the second comparator 220 receives the second preliminary
pressure objective value
P6|l as an input and provides the second final pressure objective value
P6|l as an output. Each comparator 210, 220 is configured to determine the respective
final pressure objective value
P2|l, P6|l based on the respective preliminary pressure objective value
P2|r, P6|r and one or more thermofluidic property objective value thresholds as described in
further detail below.
[0101] The first comparator 210 is configured to determine the first final pressure objective
value
P2|l in accordance with conditional Equation (16) below. Namely, the first comparator
210 is configured to set the first final pressure objective value
P2|l as being equal to the first preliminary pressure objective value
P2|r if (e.g., when) the first preliminary thermofluidic property objective value
P2|r is in a range between a first lower thermofluidic property objective value threshold
P2|th,l and a first upper thermofluidic property objective value threshold
P2|th,u inclusive. Further, the first comparator 210 is configured to set the first final
pressure objective value
P2|l as being equal to the first lower thermofluidic property objective value threshold
P2|th,l if (e.g., when) the first preliminary thermofluidic property objective value
P2|r is less than the first lower thermofluidic property objective value threshold
P2|th,l. Additionally, the first comparator 210 is configured to set the first final pressure
objective value
P2|l as being equal to the first upper thermofluidic property objective value threshold
P2|th,u if (e.g., when) the first preliminary thermofluidic property objective value
P2|r is greater than the first upper thermofluidic property objective value threshold
P2|th,u.
[0102] More specifically, and as an example, in order to enforce the thermofluidic constraints
discussed above for a transcritical regime, the first lower thermofluidic property
objective value threshold
P2|th,l may be defined in accordance with Equation (16a) and the first upper thermofluidic
property objective value threshold
P2|th,u may be defined in accordance with Equation (16b).

[0103] As another example, in order to enforce the thermofluidic constraints discussed above
for a subcritical regime, the first lower thermofluidic property objective value threshold
P2|th,l may be defined according to Equation (16c) and the first upper thermofluidic property
objective value threshold
P2|th,u may be defined according to Equation (16d).

[0104] In a similar way, the second comparator 220 is configured to determine (e.g., set)
the second final pressure objective value
P6|l in accordance with conditional Equation (17) below. Namely, the second comparator
220 is configured to set the second final pressure objective value
P6|l as being equal to the second preliminary pressure objective value
P6|r if (e.g., when) the second preliminary thermofluidic property objective value
P6|r is in a range between a second lower thermofluidic property objective value threshold
P6|th,l and a second upper thermofluidic property objective value threshold
P6|th,u inclusive. Further, the second comparator 220 is configured to set the second final
pressure objective value
P6|l as being equal to the second lower thermofluidic property objective value threshold
P6|th,l if (e.g., when) the second preliminary thermofluidic property objective value
P6|r is less than the second lower thermofluidic property objective value threshold
P6|th,l. Additionally, the second comparator 220 is configured to set the second final pressure
objective value
P6|l as being equal to the second upper thermofluidic property objective value threshold
P6|th,u if (e.g., when) the second preliminary thermofluidic property objective value
P6|r is greater than the second upper thermofluidic property objective value threshold
P6|th,u.
[0105] More specifically, in order to enforce the thermofluidic constraints discussed above
for a transcritical regime, the second lower thermofluidic property objective value
threshold
P6|th,l may be defined in accordance with Equation (17a) and the second upper thermofluidic
property objective value threshold
P6|th,u may be defined in accordance with Equation (17b). The same definitions may be used
for a subcritical regime.

[0106] Figure 8 is a schematic diagram showing a detailed block diagram of the inner control logic
800. The inner control logic 800 includes determining, at block 810, a pressure error
array
ΔP2, ΔP6 as being a difference between the final pressure objective value array
P2|l, P6|l and system pressure array
P2, P6.
[0107] In a similar way to the outer control logic 300, the inner control logic 800 includes
a proportional-integral (PI) action, represented by blocks 820, 830, 840 and 850,
for determining the preliminary actuator operating parameter objective array
ωc|r,
u v|r. The PI action is carried out with the intention of reducing each pressure error
value (ideally to zero). The inner control logic 800 further includes an anti-windup
action for correcting possible wind-up associated with the integral aspect of the
PI action, which is implemented by application of a backstepping gain as described
in further detail below. That is, including the integral aspect in the PI action may,
in turn, cause problems when the final pressure objective values
P2|l, P6|l are effectively unattainable and/or due to the action of the actuator operating parameter
objective limiting logic 900 described below. In this case, the pressure error array
ΔP2, ΔP6 will tend to keep increasing, causing the so-called windup effect. Therefore, an
anti-windup action is also included, synthesized using a backstepping gain
Kp b as explained in further detail below.
[0108] To capture possible wind-up associated with any unattainability of the final pressure
objective values
P2|l,
P6|l and the action of the actuator operating parameter objective limiting logic 900,
the backstepping gain
Kpb is applied in respect of the final actuator operating parameter objective array
ω c|l, u v|l.
[0109] The application of a proportional gain
Kpp to the pressure error array
ΔP2, ΔP6 to produce a proportional preliminary actuator parameter term array
ω c|rp, u v|rp is represented by block 820. The preliminary actuator operating parameter objective
array
ω c|r,
u v|r, is subtracted from the final actuator operating parameter objective array
ω c|l, u v|l at block 860 to yield a backstepping actuator operating parameter array
ω c b, u v b. In turn, the application of a backstepping gain
Kpb to the backstepping actuator operating parameter array
ω cb, u vb to produce a backstepping pressure array
P2b, P6b is represented by block 870. The pressure error array
ΔP2, ΔP6 and the backstepping pressure array
P2b, P6b are added at block 880 to produce a backstepped pressure error array
ΔP2 b, ΔP6 b. The time-integration of the backstepped pressure error array
ΔP2b, ΔP6b and the application of an integral gain
Kpi to an time-integral pressure array to produce an integral preliminary actuator parameter
term array
ω c|r i,
u v|r i is represented by blocks 830 and 840, respectively. The proportional preliminary
actuator parameter term array
ω c|r p,
u v|rp and the integral preliminary actuator parameter term array
ω c|r i, u v|r i are then added, as represented by block 850, to produce the preliminary actuator
operating parameter objective array
ωc|r,
u v|r.
[0110] As a result, the preliminary actuator operating parameter objective array
ω c|r,
u v|r is determined based on both the final pressure objective value array
P2|l, P6|l and the final actuator operating parameter objective array
ω c|l, u v|l. Each of the gains
Kpp, Kpb, Kpi described above are in the form of 2 by 2 matrices, and application of the gains
Kpp, Kpb, Kpi at blocks 820, 840 and 870 is performed using matrix multiplication of the relevant
arrays and gain matrices.
[0111] It follows that each of the preliminary compressor operating parameter objective
value
ωc|r and the preliminary expansion device operating parameter objective value
u v|r are determined based on both the first final pressure objective value
P2|l and the second final pressure objective value
P6|l. In other words, the preliminary compressor operating parameter objective value
ωc|r is influenced by both the first final pressure objective value
P2|l and the second final pressure objective value
P6|l and the preliminary expansion device operating parameter objective value
uv|r, is influenced by both the first final pressure objective value
P2|l and the second final pressure objective value
P6|l. For this reason, the inner control logic 800 described with respect to Figures 2
and 8 may be referred to as a multivariable inner control logic 800 or a multiple-input
multiple-output (MIMO) inner control logic 800.
[0112] This multivariable nature of the inner control logic 800 addresses coupling effects
when using both actuators 402, 406 simultaneously and allows for faster time responses
to changes in the operating conditions of the vapour-compression system 400. Further,
including an anti-windup action in the multivariable inner control logic 800 permits
the minimisation of the pressure error array
ΔP2, ΔP6 (in a multivariable sense) in case of one of the actuators 402, 406 becoming saturated
(e.g., due to the action of the actuator operating parameter objective limiting logic
900).
[0113] Figure 9 is a schematic diagram showing a detailed block diagram of the actuator operating
parameter objective limiting logic 900. The actuator operating parameter objective
limiting logic 900 is generally adapted to enforce safe and effective operating parameter
constraints for the actuators 402, 406.
[0114] The actuator operating parameter objective limiting logic 900 is shown as comprising
a compressor parameter comparator 910 and an expansion device parameter comparator
920. The compressor parameter comparator 910 receives the preliminary compressor operating
parameter objective value
ω c|r as an input and provides the final compressor operating parameter objective value
ω c|l as an output. In a similar way, the expansion device parameter comparator 920 receives
the preliminary expansion device operating parameter objective value
u v|r as an input and provides the final expansion device operating parameter objective
value
u v|l as an output.
[0115] The compressor parameter comparator 910 is configured to determine the final compressor
operating parameter objective value
ω c|l based on the preliminary compressor operating parameter objective value
ωc|r and one or more compressor speed objective value thresholds. The one or each compressor
speed objective value threshold may be defined according to physical limitations of
the compressor 402 or maximum recommended operational conditions for the compressor
402, the latter being recommended for safety and/or performance purposes. Similarly,
the expansion device parameter comparator 920 is configured to determine the final
expansion device operating parameter objective value
u v|l based on the preliminary expansion device operating parameter objective value
uv|r, and one or more expansion device operating parameter objective value thresholds.
The one or each expansion device operating parameter objective value threshold may
be defined according to physical limitations of the expansion device 406 or maximum
recommended operational conditions for the expansion device 406, with the latter being
recommended for safety and/or performance purposes in a similar way to that described
immediately above with respect to the compressor 402.
[0116] Preferred embodiments of the present disclosure relate to a two cascaded control
loop method for controlling a vapour-compression system 400, with a pressure limiting
logic which is configured to enforce particular thermofluidic constraints. This is
associated with a variety of advantages as follows.
[0117] Organising the controller 490 in two cascaded control logics (e.g., inner and outer
control logics 300, 800) and choosing the pressure as intermediate variable (that
is, as the variable which links both control logics 300, 800), enables explicit thermofluidic
constraint enforcement in the pressure domain. More particularly, these thermofluidic
constraints will be implicitly enforced by the inner control logic 800 when the inputs
thereto are selectively limited by the pressure limiting logic 200. Managing system
constraints in an explicit manner is a preferred strategy in practical industry, in
contrast to "indirect" constraints handling techniques such as model predictive control.
[0118] The arrangement described herein for the pressure limiting logic 200 allows for the
translation of any superheat, subcooling, temperature and/or pressure conditions into
the pressure domain, by a set of transformations using appropriate fluid functions.
These transformations allow to define the minimum and maximum values for the two system
pressures in an intuitive manner, providing a better understanding on the conditions
to be imposed on the working fluid for safe and/or efficient operation of the vapour-compression
system 400.
[0119] The configuration of the outer control logic 300 and/or the inner control logic 800
as multivariable control logics enables more effective control performance, as any
coupling between physical effects in the vapour-compression system 400 caused by the
different actuators is attenuated. This enables improved multivariable performance
of the controller 490. Further, the present disclosure described the addition of an
observer-based anti-windup action to each control logic, which in the case of the
outer control logic 300, does not rely on any transformations to signals associated
with the inner control logic 800, but instead directly uses the measurements from
the vapour-compression system 400. The design of each of the outer and inner control
logic gains is straightforward using readily available synthesis tools, permitting
an intuitive tuning process.
[0120] Since the thermofluidic constraints are explicitly managed by the pressure limiting
control logic 200, there is no need to dedicate one of the actuators 402, 406 to track
(e.g., maintain) a specific level of superheat (which is the common rule of thumb
in the technical field). Instead, in accordance with the present disclosure, the two
degrees of freedom of control available in the vapour-compression system 400 (which
are the two pressures in the outer-loop controller), can be entirely devoted to attempting
to track two different temperature targets in two thermal sources 407A, 407B, attached
to separate evaporators 408A, 408B that may be arranged in series as shown in Figure
2 (and are therefore effectively working at the same pressure). This provides a benefit
of allowing cooling of an additional source to be provided by the vapour-compression
system 400 without significantly increasing system complexity or compromising system
safety.
[0121] Although it has been described, with reference to the accompanying drawings, that
the outer control logic 300 and the inner control logic 800 each include a PI action,
this need not necessarily be the case. Namely, this disclosure contemplates that either
or both of the outer control logic 300 and the inner control logic 800 may include
additional and/or alternative actions, such as a proportional-integral-derivative
(PID) action or a linear-quadratic regulation (LQR) action. The methodologies described
herein are equally applicable to such actions, including the application of backstepping
gain(s) as discussed above.
[0122] The present disclosure also anticipates that the respective temperatures
Ta, Tb of the thermal sources 407A, 407B may be predicted based on other parameters of the
thermal sources 407A, 407B rather than being directly monitored using temperature
sensing apparatus. For instance, if the or each thermal source 407A, 407B comprises
an electrical device, the temperatures
Ta, Tb of the thermal sources 407A, 407B may be predicted based on a power consumption of
the or each electrical device.
[0123] Figure 10 shows a schematic arrangement of a second example vapour-compression system 400'
and a block diagram for a second example controller 490'. The second example vapour-compression
system 400' is generally similar to the first example vapour-compression system 400
described above with reference to Figure 2, with like reference signs indicating common
or similar features. Likewise, the second example controller 490' is generally similar
to the first example controller 490, with like reference signs denoting common or
similar features.
[0124] However, in the second example controller 490', the functionality of the outer control
logic 300, the pressure limiting logic 200, the inner control logic 800 and the actuator
operating parameter objective limiting logic 900 described with respect to the first
example controller 490' is split between a pair of outer control logics 300, 300',
a pair of pressure limiting logics 200, 200', a pair of inner control logics 800,
800' and a pair of actuator operating parameter objective limiting logics 900, 900'.
[0125] That is, each outer control logic 300, 300' is configured to receive a respective
source temperature
Ta, Tb from the signal processing module 495 as an input and to provide a respective preliminary
pressure objective value
P2|r, P6|r as output to the corresponding pressure limiting logic 200, 200'. In turn, the pressure
limiting logics 200, 200' are each configured to receive a respective system temperature
T2, T6, a respective preliminary pressure objective value
P2|r, P6|r and a respective system pressure
P2, P6 from the signal processing module 495 as inputs and to provide a respective final
pressure objective value
P2|l,
P6|l as an output to the inner control logic 800, 800'. Each inner control logic 800,
800' is configured to receive a respective system pressure
P2, P6 and a respective final pressure objective value
P2|l, P6|l as inputs and to provide a respective preliminary actuator operating parameter objective
ω c|r, u v|r as an output to the respective actuator operating parameter objective limiting logic
900, 900'. Lastly, the actuator operating parameter objective limiting logics 900,
900' are each configured to receive a respective preliminary actuator operating parameter
objective
ωc|r,
u v|r as an input and to provide a respective final actuator operating parameter objective
ω c|l,
u v|l as an output to the respective actuator 402, 406 of the vapour-compression system
400.
[0126] Consequently, in the example of Figure 10, each outer control logic 300, 300' may
be referred to as a univariable outer control logic 300, 300' or a single-input single-output
(SISO) outer control logic 300, 300'. For the same reasoning, each inner control logic
800, 800' may be referred to as a univariable inner control logic 800, 800' or a single-input
single-output (SISO) inner control logic 800, 800'.
[0127] In particular, each one of the pairs of control logics forms a part of a separate
control path of the controller 490'. A first control path comprises a first of the
outer control logics 300, a first of the pressure limiting logics 200, a first of
the inner control logics 800 and a first of the actuator operating parameter objective
limiting logics 900. Conversely, a second control path comprises a second of the outer
control logics 300', a second of the pressure limiting logics 200', a second of the
inner control logics 800' and a second of the actuator operating parameter objective
limiting logics 900'. The first control path relates to control of the expansion device
406 alone, whereas the second control path relates to control of the compressor 402
alone. In some examples in accordance with the present disclosure, each control path
may be implemented using a separate controller and/or a separate processor.
[0128] Figure 11 shows a schematic arrangement of a third example vapour-compression system 400" and
a block diagram for a third example controller 490". The third example vapour-compression
system 400' is generally similar to the first example vapour-compression system 400
described above with reference to Figure 2 and the second example vapour-compression
system 400' described above with reference to Figure 10, with like reference signs
indicating common or similar features. Likewise, the third example controller 490"
is generally similar to the first example controller 490 and the second example controller
490', with like reference signs denoting common or similar features.
[0129] Nevertheless, in contrast to the first example vapour-compression system 400 and
the second example vapour-compression system 400', the third example vapour-compression
system 400" comprises only a single evaporator 408A. As a consequence, the third example
controller 490" is configured differently to the first example controller 490. Namely,
the outer control logic 300 is configured to only receive the first source temperature
Ta from the signal processing module 495 as an input and to provide the first preliminary
pressure objective value
P2|r as output to the pressure limiting logic 200. Moreover, the pressure limiting logic
200 is only configured to receive the first system temperature
T2, the first preliminary pressure objective value
P2|r and the system pressure array
P2, P6 from the signal processing module 495 as inputs and to provide the first final pressure
objective value
P2|l as an output to the inner control logic 800. The inner control logic 800 is also
configured to receive the second final pressure objective value
P6|r from a dedicated pre-processing logic 496, such that the inner control logic 800
is configured to receive the complete final pressure objective value array
P2|l, P6|l. Accordingly, in the example of Figure 11, the outer control logic 300 is as a univariable
outer control logic 300 as described with respect to Figure 10 while the inner control
logic 800 is as a multivariable inner control logic 800 as described with respect
to Figure 2.
[0130] The dedicated pre-processing logic 496 is configured to receive the second system
temperature
T6 from the appropriate system sensing arrangement and to output the second final pressure
objective value
P6|r to the inner control logic 800. The dedicated pre-processing logic 496 determines
the second final pressure objective value
P6|r based on the second system temperature
T6 by application of Equation (18), where

is the superheat setpoint for the working fluid at the sixth monitoring location
6, and the function
Psat is as described above in respect of the examples of Figures 5 to 7.

[0131] Figure 12 shows, highly schematically, a machine-readable medium 600 having stored thereon
a computer program 60 comprising instructions which, when executed by the controller
490 provided to a vapour-compression system in accordance with the example vapour-compression
systems as described above with reference to Figures 2, 10 and 11, cause the controller
490 to execute a method of controlling the vapour-compression system as described
herein with reference to Figures 2 to 11.
[0132] Various examples have been described, each of which feature various combinations
of features. It will be appreciated by those skilled in the art that, except where
clearly mutually exclusive, any of the features may be employed separately or in combination
with any other features and the disclosure extends to and includes all combinations
and subcombinations of one or more features described herein.
[0133] The examples described above have been provided in the context of vapour-compression
systems comprising either a single evaporator 408 or both a primary evaporator 408A
and a secondary evaporator 408B (i.e., both primary evaporator 408A and a secondary
evaporator 408B). Nevertheless, this disclosure envisages that the methodologies described
herein may be applied to vapour-compression systems comprising more than two evaporators.
That is, vapour-compression system in accordance with the present disclosure may comprise
more than one additional evaporators, with each optionally being configured to facilitate
heat transfer from a respective additional thermal source into the working fluid,
and methods of control thereof may include controlling the compressor, the expansion
device and/or additional actuators provided to the vapour-compression system (e.g.,
valves) in accordance with the methodologies described herein.
[0134] It will also be appreciated that whilst the disclosure has been described with reference
to aircraft and aircraft propulsion systems, the techniques described herein could
be used for many other applications. These include, but are not limited to, automotive,
marine and land-based applications.