TERM PAPER ON

CONTROL SYSTEMS IN REFRIGERATION AND AIR

CONDITIONING

SUBMITTED TO: SUBMITTED BY:

Mr. VIJAY SHANKAR AJAY KUMAR
SECTION: B4801
ROLLNO: 25
REG. NO.: 10805661
CONTENTS

 INTRODUCTION

 REFERIGERATION SYSTEM

 TRENDS IN REFRIGERATORS

 AIR CONDITIONER SYSTEM

 ENERGY EFFICIENCY
 POWER FACTOR CORRECTION (PFC)

 HIGH-VOLTAGE ISOLATION

 INTEGRATION
 HOME NETWORK

 POWER MANAGEMENT
 INDUCTION MOTOR CONTROLLER

 TEMPERATURE CONTROL SYSTEM

 DEFROST CONTROLLER SYSTEM

 TESTING THE TECHNOLOGY

 MOISTURE AND THE HUMIDITY CONTROLLER

 DUCT CONTROLLER

 ELECTRONIC CONTROLLER
INTRODUCTION

REFERIGERATION SYSTEM
Today’s refrigerators are more energy efficient, are quieter, and are smarter than the ones
developed in years past. Texas Instruments has developed products to meet the challenges
and requirements for these new sophisticated systems.

Energy Efficiency: Home appliance (a.k.a. white goods) motors are often oversized to
account for the load torque changes and transients. Scalar techniques for control can result in
inefficient systems and noisy operation. This, in turn, leads to a mediocre energy efficiency
that hovers in the 40% to 50% range. By implementing the control system with TI’s digital
signal controllers, designers are able to implement smaller, quieter motors with energy
efficiency as high as 85% - 90%. A high efficiency is necessary to receive a stamp of
approval from a governing body such as the US Environmental Protection Agency and
Department of Energy ENERGY STAR rating.

High-Voltage Isolation: For larger, higher-performance products where reliability and motor-
control accuracy are key concerns, TI offers isolation products that block high voltage, isolate
grounds, and prevent noise currents from entering the local ground and interfering with or
damaging sensitive circuitry.
TRENDS IN REFRIGERATORS:
A home mesh network consisting of home appliances, audio/video equipment, HVAC
system, lighting fixtures, etc connected wirelessly and controlled via a remote control sounds
futuristic but can be done. Manufacturers can develop tomorrow’s products that communicate
with each other by creating intelligent home networks such that, for example, a wash load is
completed and a message be displayed on your TV, or LCD display on your refrigerator or
remote control.

 Does not require line-of-sight

 Has an increased range such that one can remotely control any device from anywhere
in the home
 Allows for two-way communication

Refrigerators have separate systems that are responsible for different features. However, not
all refrigerators have all systems. To look for information about the operation of your
refrigerator, click one of these topics:
 Automatic defrost
 Cooling
 Temperature control
 Lighting
 Icemaker
 Ice and water dispenser
 Door seals and hinges
The defrost heater is similar to the burners on an electric stove. It's located just beneath the
cooling coils, which are concealed behind a panel in the freezer compartment. The heater gets
hot. And, because it's close to the cooling coils, any ice or frost build-up melts.
As the frost and ice melt, the resulting water drips into a trough. The trough is connected to a
tube that drains the water into a shallow pan at the bottom of the refrigerator. The water is
then evaporated by a fan that blows warm air from the compressor motor over the pan and
out the front of the refrigerator.

COOLING
You'll more quickly understand refrigerator cooling systems if you think of their action as,
removing heat from the air in the refrigerator" rather than "cooling the air in the refrigerator.
All residential refrigerators work on the same principal for cooling. They all have:
 A Compressor
 A Condenser
 A Metering Device (Capillary Tube)
 An Evaporator

TEMPERATURE CONTROL SYSTEM

All refrigerators have a thermostat to maintain the proper temperature. These are usually very
simple devices. When the refrigerator reaches the set temperature, the thermostat interrupts
the electricity flow to the compressor, which stops cooling.
LIGHTING
Refrigerators with internal lighting normally have only one functional component--the
switch--which is usually a white push-button mounted inside the refrigerator near the door.
When the refrigerator door closes, the door pushes the switch to turn the light off. When the
door opens, the button automatically pops back out to turn on the light. The light bulb itself is
usually a standard appliance bulb.

ICEMAKER
The ice maker is a small appliance within a freezer. It's usually independent of the other
systems of the refrigerator. Ice maker systems have two basic functional components: the
icemaker itself and the water fill valve.
The ice maker sends a signal to the water fill valve (normally located on the outside back of
the refrigerator, near the bottom) to open and let water into the ice maker tray. The amount of
water is determined by a cam and switch within the ice maker control panel. The icemaker
sends the signal to open the water valve for a certain length of time (7-10 seconds) then stops
the signal.
While the ice maker is dumping the cubes into a holding bin, a metal wire similar to a coat
hanger swings up to let the cubes drop below it. When the cubes have dropped, the wire
comes back down. If the holding bin is full of ice, the wire cannot come all the way back
down, which stops further production of ice.

DOOR SEALS AND HINGES

All refrigerator/freezer doors have a seal--a rubber-like gasket attached to the door. Usually
white, almond, black, or brown, the seal's job is to keep the cool air inside the refrigerator and
the room air out.
The seal is lined with a magnet that runs its length and width. The magnet helps to hold the
door closed and create a tight seal. The screws that hold the seal to the door also hold the
door liner in and help to "square" the door.
The hinges allow the door to swing open. Some hinges also assist the door in closing. For the
door to close properly, the hinges must be correctly adjusted.

AIR CONDITIONER SYSTEM

Heating, ventilation, and air conditioning (HVAC) systems are becoming more sophisticated
as manufacturers design features into the product that make them more reliable, quieter, more
efficient, and with a higher comfort level in ambient temperature.

ENERGY EFFICIENCY:
Digital signal controller systems save energy. Since most air conditioners operate with a light
load, an inverter-controlled air conditioner can adjust the compressor motor speed for a light
load by changing the frequency. This allows designers to use a high-efficiency compressor
motor in the outdoor unit of the air conditioner.

POWER FACTOR CORRECTION (PFC):

PFC is a technique of counteracting the undesirable effects of electric loads that create a
power factor that is less than

PFC is needed because of the continuous transients and surge currents exhibited by the
electric motor, and it is also used to boost the rectified mains voltage up to 300 V to 450 V,
which is then used to power the 3-phase inverters which ultimately operate the electric motor.
With TI products, PFC can be performed externally with a separate integrated circuit or it can
be done in the digital signal controller eliminating the need for a separate external PFC
controller.

HIGH-VOLTAGE ISOLATION:
For larger, higher-performance systems where reliability and motor-control accuracy are key
concerns, TI offers isolation products that block high voltage, isolate grounds, and prevent
noise currents from entering the local ground and interfering with or damaging sensitive
circuitry.

INTEGRATION:
Texas Instruments provides fully-integrated solutions such as the digital signal controllers
(for digital motor control, PFC, and other system functions), and relay drivers that provide up
to 8 channels, zero-volt detection, and 5 V linear regulation for 5 V logic that may reside on
the board.

HOME NETWORK:
A home mesh network consisting of home appliances, audio/video equipment, HVAC
system, lighting fixtures, etc connected wirelessly and controlled via a remote control is
possible today with the products. TI provides customers with industry-leading compliant
solutions and a broad range of proprietary RF-ICs that enable innovative low-power RF
applications. HVAC and thermostat (or indoor controller unit) manufacturers can develop
products that wirelessly communicate with each other. Furthermore, temperature settings can
be controlled via a remote control unit. With low-power wireless solutions from TI, home
owners will benefit from a universal remote control that:

 Does not require line-of-sight

 Has an increased range such that one can remotely control any device from anywhere
in the home.

 Allows for two-way communication.

POWER MANAGEMENT:
Offline 24 V power supply lines are typically available in most homes. TI offers buck
controllers and linear regulators that convert this offline voltage to something the
microcontroller on the thermostat or indoor controller unit can use either 3.3 V or 1.8 V
typically.

INDUCTION MOTOR CONTROLLER

The use of PI controllers for speed control of induction machine drives is
characterized by an overshoot during tracking mode and a poor load disturbance
rejection. This is mainly caused by the fact that the complexity of the system does not
allow the gains of the PI controller to exceed a certain low value. At starting mode the
high value of the error is amplified across the PI controller provoking high variations
in the command torque. If the gains of the controller exceed a certain value, the
variations in the command torque become too high and will destabilize the system.

To overcome this problem we propose the use of a limiter ahead of the PI controller.
This limiter causes the speed error to be maintained within the saturation limits
provoking, when appropriately chosen, smooth variations in the command torque
even when the PI controller gains are very high.
In this paper, a new approach to control the speed of an indirect field oriented
induction machine drive using a classical PI controller is proposed. Its simulated input
– output non linear relationship is then learned off – line using a feed – forward linear
network with one hidden layer.
The simulation of the system using either the modified PI controller or the learned
neural network controller shows promising results. The motor reaches the reference
speed rapidly and without overshoot, step commands are tracked with almost zero
steady state error and no overshoot, load disturbances are rapidly rejected and
variations of some of the motor parameters are fairly well dealt with.
Induction motor drive, Field orientation control, PI controller, Speed control

With the apparition of the indirect field oriented control (FOC), induction machine drives are
beginning to become a major candidate in high performance motion control applications. In
the complex machine dynamics, this decoupling technique permits independent control of the
torque and the field.

PID classical controllers find some difficulties in dealing with the detuning problem. The
complexity of the system does not allow the gains of the PID controllers to exceed a certain
value causing the controller to deal very poorly with the detuning problem. At starting mode
the high value of the error is amplified across the PI controller provoking high variations in
the command torque which will destabilizes the system for high controller gains values. To
overcome this problem we propose to use a limiter at the input of the controller in order to
allow the system to accept high values of the PID controller gains.

In this paper an original PI based controller for speed adjustment of an indirect field oriented
voltage fed induction machine drive is presented.

It’s simulated input-output non linear relationship is then learned offline using an appropriate
neural network in order to realise a robust neural controller.

rotor stator and mutual inductance

rotor and stator resistance
T* torque command
rotor flux component command
J rotor inertia referred to motor shaft
B viscous friction coefficient
P number of pole pairs
stator electrical angle
electrical synchronous speed
electrical rotor speed
rotor speed
slip speed
speed error
direct and quadrature component of stator voltage command
phase voltage

PROPOSED ORIGINAL CONTROLLER STRUCTURE

Fig.1 gives the block diagram structure of a voltage fed induction motor speed control using
indirect field oriented command scheme. To replace the controller used in this structure we
propose the original PI based controller presented by fig. 2.
 Fig. 1. Indirect field orientation control block diagram

Fig. 2. Proposed PI based controller structure

DEFROST CONTROLLER SYSTEM

Refrigerators are appliances where demand for both energy conservation and user
functionality is increasing. Looking for new ways to improve energy efficiency in
refrigerators is an important task that should not be ignored.

One area where refrigerators can improve is in the defrosting systems. Many
refrigerator/freezer systems are capable of automatic defrosting. In freezers, as the coils that
cool the air reach low temperatures, the humidity in the air condenses and freezes on the
coils, building up frost. As coils accumulate this frost, it becomes more difficult for them to
cool the air inside the freezer. This effect forces the freezer system to stay on for longer
periods of time to keep the space cold.

This is why defrost systems are installed. In a typical application, a defrost system has a
timer, a heater, and a terminator. At certain intervals, the timer turns off the condenser that is
used to cool the system and turns on the heater, which heats up the coils to melt the frost. The
terminator can be a thermostat that turns off the heater once the temperature rises to a certain
level, or it can be another timer that turns it off after a certain time. Unfortunately, this kind
of temperature cycling is not optimal for food preservation and, therefore, should be kept at a
minimum.

These cycles also consume a large amount of energy by heating up the coils and then cooling
them back down. Many companies have developed proprietary systems for adaptive defrost
control, and several patents exist on the subject. However, there is no accurate measurement
of how much frost may be present, so a freezer may try to defrost itself when in fact there is
no frost on the coils.

The change in the field creates a “capacitor” between the driving electrode and the object
within the field, each forming a “plate” that holds the electric charge. The voltage measured
on the capacitor is an inverse function of the capacitance between the electrode being
measured, the surrounding electrodes, and other objects in the electric field surrounding the
electrode. Increasing the capacitance results in decreasing voltage.

Visual representation of e-field sensor

 Block diagram of defrost system with e-field sensor.

Measurements were then taken on the e-field sensor as the freezer was turned on with no
items inside. Results showed a change in the electric field as the temperature in the freezer
decreased and, to a smaller extent, as frost formed on the sides of the wall of the refrigerator
where the plates were placed.

A metal ring electrode was then placed around the pipe that feeds the cooling coil to create a
measurement point. The pipe was straight and smooth, and frost built up at this point at the
same rate as the entire cooling coil. Measurements taken in this test showed a change in the
capacitive field as frost built up on the coil (see Figure 3). The tests showed that as frost built
up on the coil, the e-field sensor’s output voltage changed. Further tests showed that when the
freezer temperature returned to room temperature, the e-field sensor returned to its initial
readings. By monitoring the output voltage, the adaptive defrost system can better control
defrost temperature cycling to improve cooling performance and energy efficiency.
 Picture of third test setup and e-field input voltages.

MOISTURE AND THE HUMIDITY CONTROLLER

A minimum amount of condensation is normal, especially during higher humidity conditions.
If you live in a humid area, it is normal for your refrigerator to have a certain amount of
humidity on the freezer or refrigerator.

Humid room air causes moisture to build, especially when the doors are opened often. Avoid
excess moisture build-up by minimizing door openings. Get all items out at one time, keep
food organized, and close the door as soon as possible.

Improper sealing of the gaskets on the refrigerator or freezer doors could also cause humidity
to form. Check the seal around the outside doors and the freezer door to make sure nothing is
obstructing the gasket seal.

If condensation continues, adjust the temperature control colder to reduce the humidity.

Moisture may also collect on the centre mullion (divider between the freezer and refrigerator
compartments) and the refrigerator cabinet flanges during periods of high humidity. Wipe
surfaces dry as needed. Moisture on the vertical hinged seal (divider between the two
refrigerator doors) may also occur during periods of high humidity.

Energy Saver option (On select French-door models)

The refrigerator uses more energy when the Energy Saver option has been turned off because
a heater in the
vertical mullion is running to help reduce moisture. The Energy Saver feature turns off the
vertical mullion heater.

To use the Energy Saver option:

• Press the control to On to save energy when the environment is less humid.
• Press the control to Off when the environment is warm and more humid, or if
moisture is noticed on the vertical mullion.

DUCT CONTROLLER

The present invention relates to a dual duct control system for use in an environmental
control system. The dual duct control system is preferably utilized in a dual duct VAV box.
The control system advantageously receives room temperature values, mixed air flow values,
and positions the actuators in response to temperature values and flow values. The dual duct
control system preferably executes a shower algorithm implemented in software to position
the actuators. The shower algorithm provides a scheme for incrementally adjusting the hot
and cold air flow set points for the VAV box so the internal environment reaches a
comfortable temperature within a minimum amount of time.

ELECTRONIC CONTROLLER
The limit switch is found only on frost-free refrigerators and freezers. Its function is to keep
the defrost heating element from exceeding certain set temperatures. If a refrigerator has lots
of frost in the freezer compartment, the problem may be the limit switch. However, other
components -- the evaporator fan, the defrost timer, and the defrost heater -- can cause the
same problem. Check these for malfunctions, as detailed below. If these parts are in working
condition, the problem is most likely in the limit switch.

Thermostat controls regulate the temperature of the refrigerator and freezer. Remove the
control panel to reach the controls.

REFERENCES:
 http://www.repairclinic.com/Refrigerator-How-Things-Work

 http://hbd.org/mtippin/tempcont.html

 http://www.essortment.com/refrigerator-problem-repair-fix-refrigerator-temperature-
control-11776.html

 http://www.instructables.com/id/Temperature-Controlled-Freezer/

 http://www.acmehowto.com/howto/appliance/refrigerator/check/tempcontrol.php

 http://www.breworganic.com/refrigeratortemperaturecontroller.aspx