TEPZZ¥_7_Z¥5A_T

(19)

(11) EP 3 171 035 A1

(12) EUROPEAN PATENT APPLICATION

(43) Date of publication: (51) Int Cl.:

24.05.2017 Bulletin 2017/21 F04D 29/46 (2006.01) F04D 27/02 (2006.01)
F04D 29/058 (2006.01)
(21) Application number: 16197151.0

(22) Date of filing: 04.11.2013

(84) Designated Contracting States: • SCHREIBER, Jan W.

AL AT BE BG CH CY CZ DE DK EE ES FI FR GB Stewartstown, PA Pennsylvania 17363 (US)
GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO • KAUFFMAN, Justin P.
PL PT RO RS SE SI SK SM TR York, PA Pennsylvania 17403 (US)
• NENSTIEL, Kurt F.
(30) Priority: 09.11.2012 US 201261724684 P York, PA Pennsylvania 17408 (US)

(62) Document number(s) of the earlier application(s) in (74) Representative: Wolff, Felix et al
accordance with Art. 76 EPC: Kutzenberger Wolff & Partner
13799142.8 / 2 839 167 Theodor-Heuss-Ring 23
50668 Köln (DE)
(71) Applicant: Johnson Controls Technology
Company Remarks:
Holland, MI 49423 (US) This application was filed on 03-11-2016 as a
divisional application to the application mentioned
(72) Inventors: under INID code 62.
• SOMMER, Steven T.
York, PA Pennsylvania 17404 (US)

(54) VARIABLE GEOMETRY DIFFUSER HAVING EXTENDED TRAVEL

(57) An improved variable geometry diffuser (VGD)

mechanism for use with a centrifugal compressor. This
VGD mechanism extends substantially completely into
the diffuser gap so that the VGD mechanism may be
used more fully to control other operational functions.
The VGD mechanism may be used to minimize compres-
sor backspin and associated transient loads during com-
pressor shut down by preventing a reverse flow of refrig-
erant gas through the diffuser gap during compressor
shutdown, which is prevented because the diffuser gap
is substantially blocked by the full extension of the diffuser
ring. During start-up, transient surge and stall also can
be effectively eliminated as gas flow through the diffuser
gap can be impeded as load and impeller speed increase,
thereby alleviating the problems caused by startup loads
at low speeds. The VGD mechanism can be used for
capacity control as well so as to achieve more effective
turndown at low loads.
EP 3 171 035 A1

Printed by Jouve, 75001 PARIS (FR)

 1 EP 3 171 035 A1 2

Description the diffuser ring substantially across the diffuser gap to

alter fluid flow. This mitigation can be accomplished by
CROSS-REFERENCE TO RELATED APPLICATIONS extending the diffuser ring across about 75% of the dif-
fuser gap. The diffuser ring is driven by a drive ring mov-
[0001] This application claims priority from and the 5 able from a first position corresponding to the first retract-
benefit of U.S. Provisional Application No. 61/724,684, ed position of the diffuser ring, a second position corre-
entitled VARIABLE GEOMETRY DIFFUSER HAVING sponding to the second extended position of the diffuser
EXTENDED TRAVEL, filed November 9, 2012. ring, and any intermediate position between the first po-
sition and the second position. The second position is an
FIELD OF THE INVENTION 10 extended position that stabilizes the system at about 75%
of the diffuser gap so that stall is mitigated. The drive ring
[0002] The present invention is directed to centrifugal in turn is mounted to support blocks, and the drive ring
compressors, and more particularly to an improved var- is rotationally movable with respect to the support blocks,
iable geometry diffuser mechanism allowing improved which are mounted to the backside of a nozzle base plate.
control over the complete operating range of a centrifugal 15 The nozzle base plate is fixed to the housing adjacent
compressor including startup and shutdown. the impeller of the centrifugal compressor. While the var-
iable geometry diffuser design is effective during com-
BACKGROUND OF THE INVENTION pressor operation in altering flow through the diffuser gap
when the diffuser ring is in its second extended position,
[0003] Centrifugal compressors are useful in a variety 20 the diffuser ring does not sufficiently block flow during
of devices that require a fluid to be compressed, such as compressor shutdown to retard compressor backspin
chillers. The compressors operate by passing the fluid and associated transient loads or to avoid transient surge
over a rotating impeller. The impeller works on the fluid and stall during start-up as the compressor ramps up
to increase the pressure of the fluid. Because the oper- from low loads and low speeds to high speed.
ation of the impeller creates an adverse pressure gradi- 25 [0007] Use of the variable geometry diffuser generates
ent in the flow, some compressor designs include a var- a load on the diffuser ring due to a pressure differential
iable geometry diffuser positioned at the impeller exit to on the overall ring area. When the ring is in its retracted
stabilize the fluid flow during stall events, thereby miti- position, the compressed refrigerant passes over the ring
gating stall. Stall results as refrigerant flow decreases surface and very little load is encountered. However, as
while the pressure differential across the impeller is main- 30 the ring moves to its extended position into the diffuser
tained. Stall undesirably creates noise, causes vibration gap, high velocity gas passes over the face of the diffuser
and reduces compressor efficiency. ring creating a low pressure area. Higher pressure gas
[0004] Since stall conditions are present only a very in the groove of the nozzle base plate exerts a force on
small percentage of the time that the compressor oper- the back side of the ring. The load on the ring, and the
ates, the operation of the variable geometry diffuser sim- 35 rest of the variable geometry diffuser mechanism, can
ilarly has been limited, so that wear and tear, loadings be calculated. It is the difference in gas pressure on either
and other functions that affect the overall life integrity of side of the ring multiplied by the area of the ring. The
a diffuser mechanism has been limited. However, in- variable geometry diffuser of the present invention in-
creasing usage of a variable geometry diffuser mecha- cludes a relatively large diffuser ring, the operation of
nism would dramatically affect the overall reliability and 40 which must overcome substantial forces and which must
life of a diffuser mechanism. withstand substantial forces in operation. Thus, the
[0005] A diffuser design that has been effective is set mechanisms are substantial and the energy required to
forth in U.S. Patent No. 6,872,050 issued on March 29, operate these mechanisms to overcome these forces is
2005, to Nenstiel (the ’050 Patent). The ’050 Patent dis- also substantial. However, because the variable geom-
closes a variable geometry diffuser that is opened and 45 etry diffuser is engaged for only a small percentage of
closed during the operation of the compressor, is inex- the overall life of the compressor, the loads and wear and
pensive to manufacture, is easy to assemble, is simple tear experienced by the variable geometry diffuser have
to repair or replace, and provides positive engagement been acceptable.
for position determination in response to signals or com- [0008] There is a desire to increase the usage of the
mands from the controller in response to incipient stall 50 variable geometry diffuser ring so that it can be used for
conditions. more than as just a stall mitigation device. The variable
[0006] The variable geometry diffuser design of the geometry diffuser may be used for not only stall mitiga-
’050 Patent utilizes a diffuser ring movable between a tion, but also for capacity control, surge control, improved
first retracted position in which flow through a diffuser turndown, minimization of compressor backspin and as-
gap is unobstructed and a second extended position in 55 sociated transient loads during compressor shut down
which the diffuser ring extends into the diffuser gap to as well as for minimization of start-up transients. Due to
alter the fluid flow through the diffuser gap in response the increased usage of such a variable geometry diffuser,
to detection of stall. This is accomplished by extending an improved device is required to provide desirable con-

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trol enhancements to overall centrifugal compressor op- date the increased radial forces from flow past the ring
eration, while providing longevity to the variable geome- or it will not act to block gas flow effectively and may be
try diffuser experiencing increased usage. subject to operational failures. The thickness of the ring
will vary among compressors depending upon the ca-
SUMMARY OF THE INVENTION 5 pacity of the compressor, the thickness of the ring being
relative, that relation depending on several factors, the
[0009] The present invention provides a variable ge- most important being the net radial flow forces acting on
ometry diffuser (VGD) mechanism. The VGD mechanism the first, inner cylindrical surface and second, outer cy-
includes a diffuser ring extending into a diffuser gap that lindrical surface of the diffuser ring, particularly as the
mitigates stall, as expected of a VGD mechanism. How- 10 impeller slows from operational speed during shut-down
ever, the VGD mechanism of the present invention ex- or ramp-up to operational speed during start-up. Larger
tends further into the diffuser gap than prior art VGD compressors with larger impellers will generate higher
mechanisms so that the VGD mechanism of the present flow forces and experience higher loads, requiring thicker
invention may be used to control other operational func- rings. But, regardless of compressor size, reducing the
tions. Thus the VGD mechanism may be used to mini- 15 axial forces on the ring reduces the forces necessary to
mize compressor backspin and associated transient operate the VGD mechanism.
loads during compressor shut down by preventing a re- [0011] The resulting axial load on the ring ultimately is
verse flow of refrigerant gas through the diffuser gap dur- transmitted to an actuator mechanism. The actuator
ing compressor shutdown. The reverse flow of refrigerant mechanism of the present invention includes improve-
gas is prevented because the diffuser gap is substantially 20 ments that allow it to be operated in an oil free environ-
blocked by the full extension of the diffuser ring. The VGD ment, although its operation is not so restricted. The ac-
mechanism further provides for better and more efficient tuator mechanism also is modified so that the position of
compressor turn-down, reducing the need for significant the diffuser ring with respect to the opposed interior face
hot gas bypass during low cooling capacity operation. of the housing can be monitored and adjusted by a con-
During start-up, transient surge and stall also can be ef- 25 troller as needed. The associated cam track mechanism
fectively eliminated as the variable geometry diffuser ring also has been modified so that the position of the ring in
can be positioned to impede gas flow through the diffuser the diffuser gap can be determined at any time.
gap as load and impeller speed increase, thereby allevi- [0012] Not only must the ring be sufficiently thick to
ating the problems caused by startup loads at low handle the radial loads over the life of the compressor,
speeds. The VGD mechanism of the present invention 30 the ring must also interface with the opposed housing to
can be used for capacity control as well, so as to achieve provide a gap that is uniform around its circumference
more effective turndown at low loads. and must effectively mate with an interior face of the
[0010] While the diffuser ring extends across the dif- housing that also must be dimensioned to be uniform. If
fuser gap to accommodate reduced gas flow through the the gap is not substantially uniform, that is, outside of
diffuser gap during normal operation under certain con- 35 allowable tolerances, pressurized gas will leak through
ditions, the diffuser ring must extend substantially com- the gap at locations where the gap is larger than allow-
pletely across the diffuser gap during shut-down and able, defeating the purpose of the closed diffuser ring
start-up since the gas flow is significantly reduced as the without reducing the problems related to capacity control,
impeller ramps up to speed during start-up or decreases surge, that occurs during shutdown and start-up, and oth-
its speed during shut-down. The outer edge of the diffuser 40 er operational improvements associated with the im-
ring comprises a flange that, when fully extended across proved VGD mechanism. Whereas elimination of such
the diffuser gap, substantially impedes gas flow through leakage around the diffuser ring during shut down and
the diffuser gap. The axial force on the diffuser ring is a start-up was not an imperative with prior art designs, to
function of the pressure differential on either side of the be effective, both the diffuser ring and the opposed inte-
ring and the area of the ring. When the diffuser ring is 45 rior face of the housing of the present invention must
extended into the diffuser gap, high velocity gas passes have carefully controlled mating surfaces so that proper
over the outer face of the ring creating a low pressure operation of the VGD mechanism can be accomplished
area. Higher pressure gas on a first side of the ring pro- over a range of conditions.
vides a force on the first side of the ring. The overall axial [0013] Thus, in the present invention, in order to affect
force on the ring is the difference in gas pressure between 50 control of gas flow through the diffuser gap, physical
the first side of the ring and the second, opposite side of changes extending the travel of the diffuser ring into the
the ring multiplied by the radial face area of the ring. The diffuser gap are required for the VGD mechanism. In ad-
axial force on the ring may be minimized by reducing the dition to extending the length of the diffuser ring into the
area of the ring. By reducing the radial width of the ring diffuser gap to allow substantially full closure of diffuser
extending into the diffuser gap, the axial force on the ring 55 gap, the radial area of the diffuser ring is reduced to re-
is reduced proportionally to the width of the ring. While duce the axial forces on the ring in response to the pres-
the width (thickness) of the ring may be reduced to lower sure forces. Also, by inclusion of sensors, a controller
the load, the ring must be sufficiently thick to accommo- can now monitor the position of the diffuser ring accu-

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rately and direct the actuator mechanism to accurately mechanism having a movable diffuser ring 130 to control
move the diffuser ring between positions that are fully the flow of fluid through a diffuser gap 134 such as dis-
open and fully closed in response to compressor oper- closed in U.S. Patent No. 6,872,050, assigned to the as-
ating conditions. Faster-acting mechanisms can be used signee of the present invention and incorporated herein
to achieve better control of the ring position and respond 5 in its entirety by reference. Figure 1 generally represents
to chiller system transients such as startup with pressure current state-of-the-art variable capacity centrifugal com-
differential across the compressor or power failure shut- pressors.
downs. [0018] As illustrated in Figure 1, compressor 100 in-
[0014] An additional benefit of the improved variable cludes diffuser plate 120 which, as shown, is integral with
geometry diffuser of this invention is the elimination of 10 the compressor housing, an impeller 122, and a nozzle
the need for pre-rotation vanes for capacity control and base plate 126. A diffuser ring 130, part of the variable
startup management. Pre-rotation vanes and their mech- geometry diffuser 110, is assembled into a groove 132
anisms are complex, expensive, and require their own machined into nozzle base plate 126 and mounted onto
drive mechanisms and controls. a drive pin 140. Also shown in the Figure 1 cross section
[0015] Other features and advantages of the present 15 is a cam follower 200 that is inserted into cam track 262
invention will be apparent from the following more de- which is located in drive ring 250. Cam follower 200 is
tailed description of the preferred embodiment, taken in connected to drive pin 140. These mechanisms, as is
conjunction with the accompanying drawings which illus- fully discussed in the ’050 patent, transform rotational
trate, by way of example, the principles of the invention. movement of drive ring 250 into axial movement of dif-
20 fuser ring 130. Inner circumferential groove 260 supports
BRIEF DESCRIPTION OF THE DRAWINGS an axial bearing (not shown), which resists axial move-
ment of drive ring 250 as it rotates.
[0016] [0019] Diffuser ring 130 is movable away from groove
132 and into diffuser gap 134 that separates diffuser plate
Figure 1 is a cross-sectional view of a prior art vari- 25 120 and nozzle base plate 126. Refrigerant passes
able geometry diffuser in a centrifugal compressor through diffuser gap 134, which is intermediate between
utilizing a movable diffuser ring. impeller 122 and volute (not shown) that receives refrig-
erant exiting diffuser 110. Refrigerant may pass through
Figure 2 provides a perspective view of a prior art the volute to an additional stage of compression or to a
diffuser ring. 30 condenser (also not shown). In the completely retracted
position, diffuser ring 130 is nested in groove 132 in noz-
Figure 3 is cross sectional view of the variable ge- zle base plate 126 and a diffuser gap 134 is in a condition
ometry diffuser of the present invention. to allow maximum refrigerant flow. In the completely ex-
tended position, diffuser ring 130 extends across diffuser
Figure 4 is a top view of the diffuser ring of the present 35 gap 134, reducing clearance for refrigerant to pass
invention. through diffuser gap 134. Diffuser ring 130 can be moved
to any position intermediate the retracted position and
Figure 5 is a cross sectional view showing load dis- the extended position.
tributions on the diffuser ring of the present invention. [0020] The rotation of impeller 122 imparts work to the
40 fluid, typically a refrigerant, entering at the impeller inlet
Figure 6 generally depicts the drive ring operation of 124, thereby increasing its pressure. As is well-known in
a variable geometry diffuser. the art, refrigerant of higher velocity exits the impeller
and passes through diffuser gap 134 as it is directed to
Figure 7 depicts the arrangement of the linear actu- a volute and ultimately to the compressor exit. Diffuser
ator to the drive ring of the present invention. 45 110, comprising diffuser plate 120, nozzle base plate 126
and diffuser gap 134 formed between diffuser plate 120
Figure 8 depicts the cam track in the circumference and nozzle base plate 126, as well as diffuser ring 130
of the drive ring of the present invention. used to adjust diffuser gap 134, reduces the velocity of
the refrigerant from impeller 122, thereby increasing the
Figure 9 depicts the cam track in the circumference 50 pressure of the refrigerant at the diffuser exit.
of the prior art drive ring. [0021] If the compressor flow rate decreases to accom-
modate, for example, a reduction in cooling demand for
DETAILED DESCRIPTION OF THE INVENTION a chiller, and the same pressure is maintained across
impeller 122, the fluid flow exiting impeller 122 can be-
[0017] The present invention sets forth an improved 55 come unsteady and may flow alternately backward and
VGD mechanism for a centrifugal compressor. Figure 1 forward to create the stall and/or surge condition dis-
depicts generally, in cross-section, a prior art variable cussed above. In response to a lower refrigerant flow, to
capacity centrifugal compressor 100 utilizing a VGD prevent a surge condition from developing, the diffuser

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gap 134 is reduced to decrease the area at the impeller 830 is assembled into the compressor as an element of
exit and stabilize fluid flow. The diffuser gap 134 can be VGD mechanism 810, first flange 833 extends toward an
changed by moving diffuser ring 130 into gap 134 to either opposed face of diffuser plate 120. It will be noted that
decrease the cross-sectional area of gap 134 or increase first flange 833 provides diffuser ring 830 with the ability
the cross-sectional area of gap 134 by moving the diffuser 5 to extend further into diffuser gap 134 than prior art dif-
ring within groove 132. However, because of the mech- fuser ring 130, as flange 833 provides an extended di-
anism used to drive diffuser ring 130, the exact position mension in the axial direction, that is, into diffuser gap
of diffuser ring in gap 134 is not known except at the 134. The axial force on diffuser ring 830 is the result of
extreme positions of the diffuser ring, that is, when fully the pressure differential across first flange 833. When
extended or fully retracted. Furthermore, because the 10 diffuser ring 830 is fully retracted, the axial force is at its
geometry of both the diffuser ring and the diffuser plate minimum since no pressure differential exists. However,
have not been carefully controlled in the invention of the when first flange 833 is extended into diffuser gap 134,
’050 patent, even when the diffuser ring 130 is fully ex- high velocity gas passes over the face of first flange 833
tended, a gap permitting leakage past the diffuser ring of the ring creating a low pressure area. Higher pressure
may still exist. The prior art diffuser ring 130 is set forth 15 gas in the groove of nozzle base plate 126 applies a
in Figures 6 and 7 of the ’050 Patent, Figure 6 of the ’050 pressure to second flange 835. The force on ring 830
Patent being reproduced herein as Figure 2. The features and on the mechanism that causes the ring to move into
are fully described in the ’050 Patent, wherein 150 is a and out of diffuser gap 134 is the difference in gas pres-
first face of diffuser ring 130, 152 is a second opposed sure multiplied by the face area of diffuser flange 833,
face of diffuser ring 130, 154 is an inner circumferential 20 as previously discussed.
wall of diffuser ring 130, 156 is an outer circumferential [0024] The axial force on ring 830 is reduced by reduc-
wall of diffuser ring 130, and 158 are apertures used to ing the overall radial thickness of first flange 833, which
assemble the diffuser ring to mating parts to facilitate its is the portion of diffuser ring 830 that extends into diffuser
movement. However, since the VGD mechanism of the gap 134 when first flange 833 is extended, the radial
’050 Patent is utilized for control of stall based on related 25 thickness of first flange being perpendicular to the direc-
noise and vibration, the configuration is acceptable for tion of gas flow in diffuser gap 134. Referring to Figure
its intended purpose, but its use for other functions is 3 and diffuser ring 830, the area of first flange 833 that
restricted. protrudes into diffuser gap 134 is reduced as compared
[0022] The improved variable geometry diffuser (VGD) to the design of prior art diffuser ring 130. The radial thick-
mechanism of the present invention will now be de- 30 ness of first flange 833 has been reduced by about 2/3,
scribed in detail with further reference to the drawings. thereby reducing the load on diffuser ring proportionally,
The VGD mechanism of the present invention performs that is, by about 2/3, since load is proportional to the face
functions in addition to controlling rotating stall and thus area of first flange 833 within diffuser gap 134.
requires a different configuration as well as a different [0025] The reduction of the radial thickness of first
control mechanism. 35 flange 833 reduces available space to attach the actuat-
[0023] The VGD mechanism 810 of the present inven- ing means that moves diffuser ring 830 from its retracted
tion is set forth in Figure 3. It has many similarities to the position to its extended position. Second flange 835 is
previous VGD mechanism; however, it also has signifi- provided to allow such attachment as shown in Figure 3.
cant differences, which differences may affect operation Second flange 835 resides in groove 837 in nozzle base
of the compressor. Diffuser ring 830 of the present in- 40 plate, second flange 835 moving in groove 837 allowing
vention has a different cross-sectional profile than prior diffuser ring flange 833 to move into and out of diffuser
art diffuser ring 130. Diffuser ring 130 is shown in per- gap 134. Groove 837 in nozzle base plate 126 is also
spective view in Figure 2 and has a rectangular cross- required to permit assembly of diffuser ring 830 to the
section. By contrast, diffuser ring 830 of the present in- VGD mechanism. A large radial gap around second
vention has an L-shaped cross- section as shown in the 45 flange 835 allows high pressure gas which enters groove
cross-section of Figure 3 and in Figure 4. Diffuser ring 837 to equalize on either side of the second flange 835,
830 includes a pair of substantially orthogonal flanges, thereby not contributing to the load associated with the
a first flange 833 extendable into diffuser gap 134 and a gas pressure on diffuser ring 830. Thus, the overall pres-
second flange 835 substantially perpendicular to the first sure loading on the diffuser ring 830 is the pressure of
flange, the second flange 835 extending substantially 50 the refrigerant acting on the area of the exposed portion
parallel to the diffuser gap and the direction of gas flow. of first flange 833 when extending into diffuser gap 134.
By substantially orthogonal flanges is meant flanges that A removable cover plate 839 is assembled to nozzle base
extend within a range that includes 90° 6 15° to each plate 126 and is provided to facilitate assembly of the
other where orthogonal flanges extend 90° to each other. diffuser ring drive mechanism. Cover plate 839 provides
The second flange extending substantially parallel to the 55 a smooth, aerodynamic surface for flow of refrigerant gas
diffuser gap and the direction of the gas flow means that as it flows to the compressor discharge, reducing the
the orthogonal flanges extend within a range that in- likelihood of turbulence in this area.
cludes 0° 6 15°, where 0° is parallel. When diffuser ring [0026] In forming flange 833, care must be taken to

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 9 EP 3 171 035 A1 10

provide flange 833 with a preselected radial thickness. compressor that employs mechanical bearings with
As depicted in Figure 5, which shows a cross-section of standard lubrication, or with centrifugal compressors uti-
diffuser ring 830 assembled to nozzle base plate 126, lizing electromagnetic bearings in a substantially lubrica-
high pressure refrigerant impacts first flange 833 when tion-free environment. Generally, the mechanism that
diffuser ring 830 is extended into diffuser gap 134, as 5 moves diffuser ring 830 is depicted in Figure 6 and in-
indicated by refrigerant flow 863. Figure 5 indicates a cludes a drive pin 140 that travels in cam track 862. Drive
radial pressure force on first flange 833. Another factor pin 140 connects second flange 835 to drive ring 850 so
to be considered in determining the radial thickness of that the rotational movement of drive ring 850 results in
flange 833 is the fatigue life of diffuser ring 830 which is the translational motion of diffuser ring 830 from a re-
exposed to sizable pressure fluctuations. In addition, in 10 versible retracted position to a reversible extended posi-
the present invention, diffuser ring 830 must extend as tion within diffuser gap 134. Drive ring 850 corresponds
closely as possible to diffuser plate 120 in order for the to drive ring 250 in Figure 1. The arrangement of drive
VGD mechanism to increase its capabilities for capacity pin 140 to cam follower 200 in the variable geometry dif-
control, improved turn down, surge control and minimi- fuser 810 of the present invention is also identical to the
zation of compressor transient loads at start up and shut 15 arrangement of prior art geometry diffuser 110, shown in
down. In order to reduce the gap as much as possible, Figure 1. Cam follower 200 attached to drive pin 140
diffuser plate 120 has carefully controlled dimensions follows cam track 862 in drive ring 850 as drive pin 140
and flange 833 must have carefully controlled tolerancing moves within cam track 862. Drive ring 850 of the present
in terms of flatness of the face of flange 833 as well as invention is identical to drive ring 250 of Figure 1 except
the face of mating diffuser plate 120. If flange 833 is too 20 for important differences in cam track geometry 262 of
thin, it may not be possible to maintain these geometric drive ring 250, best shown in Figure 9 and cam track
features within the desired tolerances, as mechanisms geometry 862 of drive ring 850, shown in Figures 6 and
such as spring-back may occur which can adversely af- 8. The attachment of drive ring 850 to diffuser ring 830
fect tolerances. Deviations from tolerances will increase is identical to the attachment of drive ring 250 to diffuser
leakage around flange and through the diffuser gap, and 25 ring 230, except for the points of connection of drive pin
prevent the VGD mechanism from being used effectively 140 to the respective diffuser rings 130 and 830. Diffuser
for capacity control, turn down, transient control during ring 830 of the present invention has a flange shaped
start up and turn down and surge, even though the VGD configuration and drive pin 140 connects to second
mechanism may retain its ability for use in stall mitigation. flange 835 of diffuser ring 830. Of course, second flange
As can be seen, diffuser ring 830, and in particular dif- 30 830 is not present in diffuser ring 130 as it is a simple
fuser ring flange 833 ideally must have a flange thickness cylindrical ring, as shown in cross- section in Figure 1.
as small as possible to minimize the forces acting on it, [0030] Referring now to Figure 7, an actuator 811 of
but must have sufficient thickness to avoid spring back the present invention operates in conjunction with a con-
during fabrication and satisfy fatigue during operation troller, so that its operation may be programmed. Actu-
while resisting the forces of gas pressure applied to it. 35 ator 811 is a linear actuator and includes a drive rod 896
[0027] It is an important aspect to operation of this mov- attached to a drive motor 898. Drive rod 896 is directly
able diffuser ring to maintain the geometric tolerances attached to the operating lever 901 attached to drive ring
so as to minimize leakage around diffuser ring 830 and 850. Linear movement of drive rod 896 in turn rotates
through diffuser gap 134 when diffuser ring 830 is fully drive ring 850.
extended. Compressors having higher refrigeration ca- 40 [0031] Referring now to Figure 8, cam tracks 862, lo-
pacities may require additional increases to the flange cated on the outer circumferential surface 252 of drive
thickness to accommodate higher pressure forces over ring 850, have a preselected width and depth to accept
wider diffuser widths to satisfy the competing design re- cam follower 200. Generally, there are three cam tracks
quirements cited above. 862 located in circumferential surface 252 of drive ring
[0028] Other considerations also affect the overall de- 45 850, although only one is shown in Figure 8. Cam tracks
sign of the variable geometry diffuser mechanism of the 862 extend from a bottom surface 258 of drive ring 250
present invention. Recent compressor designs utilize toward a top surface 256 of drive ring 850, extending at
electromagnetic bearings rather than mechanical bear- an angle between these surfaces, and preferably in a
ings commonly used in previous designs. Compressors substantially straight line. The shape of cam track 862 is
utilizing electromagnetic bearings eschew the use of oil. 50 now a ramp having a substantially preselected linear
However, some of the oil in compressors utilizing me- slope, as distinguished from the prior art cam tracks 262
chanical bearings assists in lubricating the actuator shown in Figure 9 having flats 267 and 269 at each end
mechanism used to move diffuser ring 130 in prior art of the ramp. The flats in prior art cam tracks 262 account
designs from a retracted position to an extended position for inaccurate positioning and travel capabilities of the
in diffuser gap 134. 55 original damper motor and to accommodate adjustment
[0029] The variable geometry diffuser 810 of the of the mechanism at the fully retracted position. The flats
present invention also utilizes an improved mechanism prevent damage to the mechanism at as the flats elimi-
design that is operable in either a conventional centrifugal nate the possibility of jamming at either extreme of travel,

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 11 EP 3 171 035 A1 12

and the inaccurate positioning was not a factor in the quired if impending surge or stall is detected. As used
operation and capabilities of prior art cam tracks. herein, a fully restricted diffuser gap 134 is one in which
[0032] By contrast, actuator 811, in one embodiment diffuser ring 830 is fully extended so that the opening of
a linear actuator, operating in conjunction with the linear diffuser gap 134 is at a minimum. While the design of
cam tracks 862 to control drive ring 850, which in turn 5 VGD mechanism 810 does not provide a 100% gas seal
positions diffuser ring 830 in diffuser gap 134, provides when diffuser ring 830 is in the fully extended position, it
faster action, variable speed, positional accuracy and does provide a substantial improvement over the prior
precise feedback of the position of the location of first art VGD mechanisms that provided only about a 75%
flange 833 in diffuser gap 134. The system of the present reduction in diffuser gap 134 when diffuser ring 130 was
invention allows for ready calibration of diffuser ring 830 10 in the fully extended position. The improvement of the
with respect to diffuser gap 134 at the extremes of diffuser present invention allows for leakage to be minimized to
ring 830, allowing diffuser ring 830 to be used for more such an extent that it no longer impacts chiller control of
than merely stall mitigation. Of course, the simplification turndown or start up and shut down surge. Thus, a fully
of the connections between the levers and linkages of restricted diffuser gap 134 and/or a fully extended diffuser
the actuator and the operating lever 901 attached to drive 15 ring 130 functionally is one that does not impact chiller
ring 250 provides further advantages. control of turndown or start up and shut down surge.
[0033] During initial set up of VGD mechanism 810 of [0034] The ability to rapidly position diffuser ring 830
the present invention, or whenever a follow-up calibration by actuator 811 also allows for capacity control of the
is desired, the actuator simply operates to rotate drive centrifugal compressor during normal operation. In ad-
ring 250, moving cam follower 200 from one end of travel 20 dition, the ability to control the positioning of diffuser ring
in cam track 862 toward the opposite end of travel in cam 830 so that the flow of refrigerant through diffuser gap
track 862. Any actuator or motor that can accomplish this 134 is limited permits for greater chiller turndown before
task may be used, although a device that moves cam the use of a hot refrigerant gas bypass is needed. Chiller
follower 200 quickly in cam track 862 is preferred. While turndown is defined as the minimum capacity that can
a rotary actuator is one variation that may be used, a 25 be achieved by the compressor while still allowing for
linear actuator is preferred. The ends of travel at either continuous operation without having to shut the compres-
end of cam track 862 correspond to the fully extended sor down. This is advantageous because hot gas bypass,
position of first flange 833 and fully retracted position of or other similar means, is a highly inefficient means for
first flange 833. The maximum dimension of diffuser gap achieving low compressor capacity because it requires
134 at first flange 833, which is the distance between 30 artificially loading the compressor with refrigerant flow.
diffuser plate 120 to the outer surface of cover plate 839, [0035] The rapid positioning of diffuser ring 830 by ac-
is a known distance that can be determined or measured tuator 811 also allows for swift control of gas flow through
based on manufacturing and assembly. Programming diffuser gap 134 during shut down. The refrigeration cycle
functions of a controller include the ability to store and of a chiller requires mechanical work (compressor/motor)
save the extreme positions of diffuser ring 830, the max- 35 to create a refrigerant pressure rise and move refrigerant
imum dimension of diffuser gap 134 at first flange 833 from evaporative conditions to condensing conditions.
and specifically first flange 833 with respect to diffuser During normal "soft" shut downs, the compressor speed
plate 120, cover plate 839 and actuator 811 so that not is reduced in a controlled manner to allow equalization
only the extreme positions are known, but also the open- of the pressure in evaporator and condenser shells,
ing of diffuser gap 134 at any time (based on the position 40 thereby eliminating large transient or upset conditions
of first flange 833) so that the opening at diffuser gap 134 during shut downs. However, when the system requires
can be adjusted quickly based on changing operating for an immediate shut down, such as due to loss of elec-
conditions of compressor 100. The position of diffuser trical power to the motor (power interruption, faults, safe-
ring 830 at the extremes of travel can be calibrated, and ties, etc.), there are no means to maintain the high pres-
the position of diffuser ring anywhere within these ex- 45 sure in the condenser shell. The only mechanism for the
tremes can be determined without the use of additional system pressures to balance is through a back flow of
sensors. A signal from the actuator may be used as part refrigerant from the high pressure condenser to the low
of the calibration procedure as well as to determine the pressure evaporator through the compressor. With no
position of diffuser ring 830 after calibration. Further- electrical power to the compressor, the impeller undesir-
more, if a question as the accuracy of the position of 50 ably behaves as a turbine with an energy transfer from
diffuser ring 830 should arise in the course of operation, the high pressure fluid in the condenser to the compres-
recalibration can be accomplished as desired. The pro- sor as the refrigerant pressure equalizes, flowing to the
gramming functions allow actuator 811 to operate and low pressure (evaporator) side, spinning the compressor
move diffuser ring 830 in a normal mode, the movements impeller backwards (opposite of design intent). In circum-
based on normal transients of compressor 100. However, 55 stances of loss of electrical power, battery backup to pow-
actuator 811 also may operate in a rapid mode, which er actuator 811 may be provided to assure that VGD re-
permits diffuser ring 830 to move to a fully extended po- mains operational at shutdown. In addition, bearing loads
sition in which diffuser gap 134 is fully restricted as re- can be at their highest levels during shutdown, if back-

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 13 EP 3 171 035 A1 14

spin, stall or surge occurs. The fast-acting closure of dif- a demand to lower temperature in the space significantly,
fuser gap 134 by VGD mechanism 810 avoids bearing and there is a corresponding large increase required in
stability issues at shutdown. It also relieves a portion of compressor output, diffuser gap 134 can be fully opened
these higher loads so lower load bearings can be used, to accommodate increased refrigerant flow. The position
which also translates into a cost savings because such 5 of diffuser ring 830, and hence the opening of diffuser
bearings are less expensive. Closing diffuser gap 134 gap 134 can be calibrated and the calibration results can
creates a resistance to back flow of refrigerant through be stored in the controller. Thus, when the compressor
compressor 100. demand is 100%, diffuser gap 134 can be fully open as
[0036] The rapid positioning of diffuser ring 830 by ac- diffuser ring 830 is fully retracted. A fully retracted diffuser
tuator 811 also allows for rapid control of gas flow through 10 ring 830 occurs as diffuser ring flange 833 is fully retract-
diffuser gap 134 during start up. During start up, there ed within groove 832. A fully extended diffuser ring 830
may already be a substantial load on the compressor if occurs as diffuser flange 833 is fully extended into diffuser
water pumps are already running with cold water flowing gap 134, such as at compressor shut-down. These two
through the evaporator and warm water flowing through conditions represent the extremes of compressor oper-
the condenser. In this case, a compressor can pass 15 ation.
through stall and surge until it achieves sufficient speed [0039] As noted, the controller can be programmed us-
to overcome the system pressure differences. Starting ing the position of diffuser ring 830 at these extreme po-
with a closed VGD can avoid transient surge under these sitions and a signal from the actuator that determines the
conditions. Thus, prior to start-up, a controller may auto- position of diffuser ring 830 between these extreme po-
matically instruct actuator 811 to move diffuser ring 830 20 sitions. In addition, operating conditions can be correlat-
to a fully extended position, closing diffuser gap 134. The ed to the position of diffuser ring. Thus, the controller can
controller may then instruct actuator 811 to retract diffus- be programmed to "learn" the position of diffuser ring 830
er ring 830, in accordance with a preprogrammed algo- at, for example, a water temperature leaving the evapo-
rithm if desired, from its fully extended position based on rator (cooling load). Other normally monitored and
a sensed condition, such as sensed pressure or com- 25 sensed conditions of the system can also be correlated
pressor speed. to the position of diffuser ring 830, and the actuator. In
[0037] Much of the assembly of the variable geometry addition, stall and surge preferably can be sensed using
diffuser may remain unchanged from the previous de- acoustic sensors, although sensing surge and stall is not
sign. However, in the present invention, the design is limited to use of such acoustic sensors and other meth-
modified so that a precise position of diffuser ring 830 30 ods may be utilized for determining when surge and stall
with respect to diffuser plate 120 is known at any time may be imminent. Of course, in the present invention,
during normal compressor operation, allowing the pre- since the controller can determine the position of diffuser
cise opening of diffuser gap 134 to be known at any time. ring 830 at any time, this position can be used by the
This is accomplished with a mechanism that does not controller to move diffuser ring 830 based on refrigerant
require or utilize additional process lubrication. VGD 35 flow behavior, compressor efficiency and detection of
mechanism 810 of the present invention, unlike prior art surge or stall, the effect on any of these conditions not
VGD mechanisms, preferably may be used in oil-free being linearly related to the position of diffuser ring 830.
compressors such as those utilizing electromagnetic [0040] For example, on start up, when compressor de-
bearings. However, it also may be used in compressors mand is throttled to 10%, diffuser gap 134 can be opened
that utilize oil-lubricated bearings. 40 by moving diffuser ring 830 from the fully extended
[0038] The ability to precisely position diffuser ring 830 (closed) position to a first predetermined position. It
allows fine adjustments to be made to diffuser gap 134 should be noted that the movement of diffuser ring 830
during compressor operation based on compressor de- will not always be the same for a 10% change in com-
mand and/or output (i.e., chiller cooling load and pressure pressor demand, due to the nonlinear effect of diffuser
difference between the condenser and evaporator), and 45 ring movement. Movement also depends on the initial
these fine adjustments can be programmed into the con- and final positions of diffuser ring 830. Similarly, when
troller during a calibration procedure and stored in the compressor demand is required at 50% (an increase of
controller. For example, as temperature changes in a 40% from the 10% demand above), diffuser gap 134 can
conditioned space, diffuser gap 134 can be modified to be further opened by positioning diffuser ring 830 from
correspond to the cooling demand on the chiller, the tem- 50 the first predetermined position to a second predeter-
perature changes corresponding to compressor de- mined position. In this way, an entire range of values can
mand. The demand on the compressor can be compared be stored in the controller, as required, to provide efficient
to actual compressor output. Thus, if demand is in- operation of the compressor, and these values can be
creased slightly, such as to cool the space slightly or to recalled (or further estimated) as compressor duty
maintain the space at a temperature (as outside temper- 55 changes, and diffuser ring 830 can be repositioned quick-
ature increases) and if demand requires a slight increase ly by the controller to achieve steady state operating con-
in compressor output, diffuser gap 134 can be increased ditions.
slightly. If demand is increased dramatically, such as by [0041] Once the occurrence of a detrimental event is

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detected, such as surge or stall detected by acoustic sen- within the scope of the appended claims.
sors, or loss of electric power to the system, the controller
can override the programmed settings and quickly extend
diffuser ring 830 into diffuser gap 134 to choke the flow Claims
of refrigerant through diffuser gap 134 until stall or surge 5
is mitigated. Although surge or stall also may be detected 1. A variable geometry diffuser (810) for a centrifugal
by monitoring refrigerant flow through diffuser 810 with compressor (100) utilizing electromagnetic bearings
sensors, the preferred way of monitoring surge or stall is in a substantially lubrication-free and/or oil-free en-
by use of acoustic sensors, as surge or stall generates vironment, the variable geometry diffuser (810) com-
significant and undesirable noise, the acoustic sensors 10 prising at least an actuator (811) and a diffuser ring
communicating with the controller. Other methods for de- (130), wherein the actuator (811) is configured to
tecting surge and stall may utilize algorithms that detect move the diffuser ring (830) from a reversible retract-
surge or stall such as set forth in U.S. Patent No. ed position to a reversible extended position within
7,356,999 entitled "System and Method for Stability Con- a diffuser (gap 134), characterized in that the ac-
trol in a Centrifugal Compressor" issued April 15, 2008, 15 tuator (811) is configured to operate in a rapid mode,
U. S. Patent No. 7,905,102 entitled "Control System" is- which permits the diffuser ring (830) to move rapidly
sued March 15, 2011. U.S. Patent No. 7,905,702 entitled to a fully extended position in which the diffuser gap
"Method for Detecting Rotating Stall in a Compressor" (134) is fully restricted to allow a capacity control
issued March 15, 2011 utilizes a pressure transducer and/or a startup management and/or a shut down
downstream of the diffuser ring to detect and correct ro- 20 management without using vanes, especially with-
tating stall. These patents are all assigned to the assign- out using pre-rotation vanes.
ee of the present invention and are incorporated herein
by reference. After surge or stall has been corrected, the 2. The variable geometry diffuser (810) of claim 1,
programmed operation of the positioning of diffuser ring wherein the capacity control and/or a startup man-
830 based on compressor demand may be restored by 25 agement and/or a shut down management com-
the controller, as discussed above. prise:
[0042] Advantages of the improved variable geometry
diffuser mechanism 810 of the present invention include -- a limitation of a flow of refrigerant through the
the use of a movable L-shaped flange 833 that reduces diffuser gap (134) for permitting a greater chiller
forces acting on the mechanism. This L-shaped flange 30 turndown; and/or
also may be lighter in weight than movable flanges uti- -- a first control of a first gas flow through the
lized in prior art variable geometry diffuser mechanisms. diffuser gap (134) during a shut down; and/or
The reduced forces and reduced weight provide for a -- a second control of a second gas flow through
VGD that can react faster. It also allows the use of lighter the diffuser gap (134) during a start up;
weight and less expensive actuators. Further, the ability 35
of the improved variable geometry diffuser to not only 3. The variable geometry diffuser (810) of one of the
fully close, but also to be calibrated to control compressor preceding claims,
operation based on sensed system conditions, allows wherein the diffuser ring (830) is extendable as
the variable geometry diffuser to be used for capacity closely as possible toward a diffuser plate (120) of
control as well as for surge and stall mitigation. This ca- 40 the centrifugal compressor (100) to increase the ca-
pacity control feature permits the elimination of pre-rota- pabilities for the capacity control.
tion vanes (PRV) which have been used in the past. Thus,
although the improved variable geometry diffuser will be 4. The variable geometry diffuser (810) of one of the
used more, the lower forces it will experience and its light- preceding claims 2-3,
er weight will result in reduced wear with longer life, which 45 wherein a radial area of the diffuser ring (830) is re-
in turn will provide increased reliability. duced to reduce axial forces on the diffuser ring (830)
[0043] While the invention has been described with ref- in response to pressure forces of the first and/or the
erence to a preferred embodiment, it will be understood second gas flow through the diffuser gap (134).
by those skilled in the art that various changes may be
made and equivalents may be substituted for elements 50 5. The variable geometry diffuser (810) of one of the
thereof without departing from the scope of the invention. preceding claims,
In addition, many modifications may be made to adapt a wherein the actuator (811) is a linear activator (811).
particular situation or material to the teachings of the in-
vention without departing from the essential scope there- 6. The variable geometry diffuser (810) of one of the
of. Therefore, it is intended that the invention not be lim- 55 preceding claims,
ited to the particular embodiment disclosed as the best wherein the diffuser ring (830) comprises a first
mode contemplated for carrying out this invention, but flange (833) being extendable into the diffuser gap
that the invention will include all embodiments falling (134) and a second flange (835) substantially per-

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pendicular to the first flange (833). er gap (134) for permitting a greater chiller turn-
down; and/or
7. The variable geometry diffuser (810) of one of the -- controlling a first gas flow through the diffuser
preceding claims, gap (134) during a shut down; and/or
wherein the variable geometry diffuser (810) further 5 -- controlling a second gas flow through the dif-
comprises a controller, wherein the controller is con- fuser gap (134) during a start up.
figured to instruct the actuator (811) to move the dif-
fuser ring (830) to the fully extended position or to 14. The method according to claim 13, wherein the meth-
retract the diffuser ring (830). od further comprises the step of:
10
8. The variable geometry diffuser (810) of claim 7, -- extending the diffuser ring (830 as closely as
wherein the controller comprises programming func- possible toward a diffuser plate (120) of the cen-
tions. trifugal compressor (100) to increase the capa-
bilities for the capacity control.
9. The variable geometry diffuser (810) of claim 8, 15
wherein, wherein the programming functions com- 15. The method according to claim 14, wherein the meth-
prise a first ability to store and save extreme positions od comprises at least one of the steps of:
of the diffuser ring (830).
-- instructing the actuator (811) to move the dif-
10. The variable geometry diffuser (810) of claim 7, 20 fuser ring (830) to the fully extended position or
wherein the programming functions comprise a sec- to retract the diffuser ring (830) by a controller;
ond ability to store and save a maximum dimension -- storing and saving extreme positions of the
of the diffuser gap (134) at the first flange (833). diffuser ring (830) by first programming func-
tions of the controller;
11. The variable geometry diffuser (810) of claim 7, 25 -- storing and saving a maximum dimension of
wherein the programming functions comprise a third the diffuser gap (134) at a first flange (833) of
ability to store and save a position of the first flange the diffuser ring (830) by second programming
(833) with respect to the diffuser plate (120) and/or functions of the controller;
the actuator (811) and/or a cover plate (839) cover- -- storing and saving a position of the first flange
ing a groove (837) in which the second flange (835) 30 (833) with respect to the diffuser plate (120)
resides. and/or the actuator (811) and/or a cover plate
(839) covering a groove (837) in which a second
12. A method for enabling a capacity control and/or a flange (835) of the diffuser ring (830) resides.
startup management and/or a shut down manage-
ment in a centrifugal compressor (100) utilizing elec- 35
tromagnetic bearings in a substantially lubrication-
free and/or oil-free environment, the method com-
prising the steps of:

-- making the diffuser ring (830) movable from 40

a reversible retracted position to a reversible ex-
tended position within a diffuser (gap 134) by an
actuator (811); and
-- operating the actuator (811) in a rapid mode
in case a stall or surge is sensed; and 45
-- moving the diffuser ring (830) rapidly to a fully
extended position in which the diffuser gap (134)
is fully restricted by the actuator (811) operating
in a rapid mode, wherein in the fully extended
position the diffuser gap (134) is closed; 50

wherein the method is free from using vanes, espe-

cially free from using pre-rotation vanes.

13. The method according to claim 12, wherein the meth- 55

od comprises the steps of:

-- limiting a flow of refrigerant through the diffus-

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REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the European
patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be
excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• US 61724684 A [0001] • US 7905102 B [0041]

• US 6872050 B [0005] [0017] • US 7905702 B [0041]
• US 7356999 B [0041]

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