Waste heat power generation control system of electric scroll compressor

Abstract

The invention relates to the technical field of electric scroll compressors, in particular to an electric scroll compressor waste heat power generation control system which comprises a waste heat collecting module, a waste heat power generation module and a waste heat power generation module. The ORC power generation module is used for converting the waste heat into electric energy; the intelligent control module is used for realizing dynamic balance and system protection of power generation and power utilization; according to the scheme, the waste heat recovery path is optimized, the phase change material and the micro-channel heat exchanger are innovatively combined, the waste heat recovery efficiency is remarkably improved, and energy waste is reduced; and a mode of combining the vortex expander and the capacitor is adopted to replace a traditional power generator, so that the size of the power generation module is effectively reduced, the power generation stability is greatly improved, and meanwhile, the power generation efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of electric scroll compressor technology, and more specifically to a waste heat power generation control system for an electric scroll compressor. Background Technology

[0002] In the field of refrigeration technology, the compressor, as the power unit of the refrigeration cycle system, is a type of driven fluid machinery whose main function is to increase low-pressure gas to high-pressure gas. Specifically, the compressor draws in low-temperature, low-pressure refrigerant gas through the suction pipe, then compresses the gas using its internal mechanical structure, and finally discharges the high-temperature, high-pressure refrigerant gas through the exhaust pipe, thereby providing power support for the entire refrigeration cycle.

[0003] During the actual operation of an electric scroll compressor, the compressor motor generates a large amount of heat. If this heat cannot be dissipated in a timely and effective manner, the motor temperature will continue to rise. Excessive temperature will accelerate the aging process of the insulation material, reduce its insulation performance, and thus affect the service life and operational reliability of the compressor. The existing solutions are generally to use water cooling or air cooling.

[0004] However, the existing solutions have the following problems:

[0005] (1) When the electric scroll compressor is running, the motor stator, compression chamber and lubricating oil and other components generate a lot of waste heat due to friction and compression. Common air-cooled or water-cooled systems simply discharge this waste heat into the environment, which undoubtedly causes a great waste of energy.

[0006] (2) Traditional waste heat recovery is mostly used for hot water production or heating, but the efficiency of converting heat energy into electrical energy is low, and it does not form a closed-loop energy utilization with the compressor control system, so it cannot achieve efficient recycling of energy.

[0007] In summary, the applicant proposed a waste heat power generation control system for an electric scroll compressor. Summary of the Invention

[0008] To achieve the above-mentioned technical objectives, the technical solution of the present invention is as follows:

[0009] An electric scroll compressor waste heat power generation control system includes:

[0010] Waste heat collection module, used to collect waste heat from the compressor casing, lubricating oil and exhaust port;

[0011] ORC power generation module, used to convert waste heat into electrical energy;

[0012] The intelligent control module is used to achieve dynamic balance between power generation and consumption and system protection.

[0013] Furthermore, the waste heat collection module includes:

[0014] A phase change material layer surrounds the compressor casing to absorb instantaneous high temperatures;

[0015] Microchannel heat exchanger, integrated into the lubrication oil circuit;

[0016] Spiral heat pipes are installed in the exhaust pipe.

[0017] Furthermore, the ORC power generation module includes:

[0018] An evaporator is used for the absorption and evaporation of a working fluid.

[0019] The vortex expander generator has a permanent magnet on the moving plate and a stator coil on the stationary plate for direct power generation.

[0020] Supercapacitors are used for energy storage and direct power supply.

[0021] The condenser and the working fluid pump complete the working fluid circulation.

[0022] Furthermore, the intelligent control module includes:

[0023] IoT controllers are used to monitor and adjust system operating parameters in real time.

[0024] The sensor array, including temperature and pressure sensors, is used for fault detection and protection switching.

[0025] An electric scroll compressor waste heat power generation control system includes the following steps:

[0026] Step S10: The compressor generates waste heat during operation, which is divided into waste heat from the casing, waste heat from the lubricating oil, and waste heat from the exhaust.

[0027] Step S20: Waste heat is collected through the waste heat collection module, namely, the waste heat of the shell is absorbed by the phase change material, the waste heat of the lubricating oil is absorbed by the microchannel heat exchanger, and the waste heat of the exhaust port is absorbed by the spiral heat pipe.

[0028] Step S30: The temperature sensor detects whether the waste heat temperature of the three components has reached the set range. If it has not reached the set range, the external power supply is switched to power the controller. If it has reached the set range, the waste heat is transferred to the evaporator, where the waste heat evaporates the low-boiling-point mixed working fluid into gas, and the next step is performed.

[0029] In step S40, the gas generated by the evaporator drives the vortex collision generator to generate electricity, and then the electrical energy is directly supplied to the controller, capacitor and vehicle battery.

[0030] Step S50: Determine whether the capacitor is overloaded by the pressure sensor. If so, switch to external power supply to power the controller. Otherwise, repeat the determination step.

[0031] Furthermore, the step S40 is followed by the following steps:

[0032] Step S41: After the evaporator absorbs the waste heat from the low-boiling-point mixed working fluid, the low-boiling-point mixed working fluid is transferred to the condenser to condense it into a liquid working fluid.

[0033] Step S42: The liquid working fluid is pressurized from low pressure to the high pressure required by the evaporator by the working fluid pump, and then sent back into the evaporator.

[0034] With improvements, the present invention further produces the following beneficial effects:

[0035] 1. This invention significantly improves waste heat recovery efficiency and reduces energy waste by optimizing the waste heat recovery path and innovatively combining phase change materials and microchannel heat exchangers.

[0036] 2. This invention uses a combination of a vortex expander and a capacitor to replace the traditional generator, which not only effectively reduces the size of the power generation module, but also greatly improves the stability of power generation and increases power generation efficiency.

[0037] 3. This invention directly supplies the electrical energy generated by the generator to the compressor control system, and uses Internet of Things technology to optimize the operating parameters, forming a closed-loop energy utilization. At the same time, the intelligent control module realizes dynamic balance between power generation and consumption and system fault protection, improving the overall system performance. Attached Figure Description

[0038] Figure 1 This is a diagram of a waste heat power generation control system for an electric scroll compressor.

[0039] Figure 2 This is a system schematic diagram of the waste heat collection module of the present invention.

[0040] Figure 3 This is a system schematic diagram of the ORC power generation module of the present invention.

[0041] Figure 4 This is a schematic diagram of the process provided by the present invention.

[0042] Figure 5 The logic control diagram provided for this invention.

[0043] Figure 6 This is a partial logic control diagram of the present invention. Detailed Implementation

[0044] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments. Example 1

[0045] like Figure 1 , Figure 2 and Figure 3 As shown, an electric scroll compressor waste heat power generation control system includes:

[0046] Waste heat collection module, used to collect waste heat from the compressor casing, lubricating oil and exhaust port;

[0047] ORC power generation module, used to convert waste heat into electrical energy;

[0048] The intelligent control module is used to achieve dynamic balance between power generation and consumption and system protection.

[0049] It should be noted that the waste heat collection module adopts a multi-stage heat source integration design concept. By setting embedded temperature sensors in different parts of the compressor, the temperature of the compressor casing, lubricating oil and exhaust port can be detected in real time and accurately.

[0050] The waste heat collection module includes:

[0051] A phase change material layer surrounds the compressor casing to absorb instantaneous high temperatures;

[0052] Microchannel heat exchanger, integrated into the lubrication oil circuit;

[0053] Spiral heat pipes are installed in the exhaust pipe.

[0054] It should be noted that the phase change material layer includes many types, such as paraffin wax. Paraffin wax has a suitable phase change temperature and a large latent heat, which can efficiently absorb and store the instantaneous high temperature heat generated by the compressor casing during operation, thus preventing the direct loss of heat.

[0055] It should be noted that microchannel heat exchangers have a small channel structure, which can increase the contact area between the lubricating oil and the working fluid, improve the heat exchange efficiency, and thus more fully absorb the waste heat carried in the lubricating oil, providing more energy for the subsequent power generation process.

[0056] It should be noted that the spiral heat absorber can increase the contact length and time with the exhaust gas, and the heat pipe technology has high heat transfer performance, which can quickly transfer the waste heat in the exhaust gas to the working fluid, enhance the heat exchange effect, and recover the waste heat of the exhaust port to the maximum extent.

[0057] The ORC power generation module includes:

[0058] An evaporator is used for the absorption and evaporation of a working fluid.

[0059] The vortex expander generator has a permanent magnet on the moving plate and a stator coil on the stationary plate for direct power generation.

[0060] Supercapacitors are used for energy storage and direct power supply.

[0061] The condenser and the working fluid pump complete the working fluid circulation.

[0062] It should be noted that, after extensive experiments and research, a low-boiling-point mixed working fluid (such as R245fa / R152a, mass ratio 85:15) was selected. This mixed working fluid has good thermophysical properties and can evaporate at a relatively low temperature, making it suitable for absorbing the waste heat generated by the electric scroll compressor. Experimental data shows that the working fluid circulation system using this mixed working fluid can achieve a thermal efficiency of 18.52%. At the same time, the evaporator evaporation temperature was optimized by setting it in the range of 105-148℃. Within this temperature range, the working fluid can fully absorb the waste heat and evaporate into high-temperature and high-pressure steam, thereby providing sufficient power for the scroll expander to drive the scroll expander to generate electricity.

[0063] In addition, when the scroll expander moves mechanically under the drive of high-pressure working fluid steam, the permanent magnet on the moving scroll moves accordingly, generating relative motion with the stator coil on the stationary scroll, cutting magnetic field lines and directly generating electrical energy. This design not only simplifies the structure and reduces the size, but also reduces energy loss in the mechanical transmission process and improves power generation efficiency. The generated electrical energy is rectified and stored in the supercapacitor bank. The supercapacitor bank can charge and discharge quickly, directly providing a stable power supply to the compressor control system.

[0064] Furthermore, for the condenser, a compact plate condenser is used. This type of condenser features a compact structure and high heat exchange efficiency, which can effectively reduce the size of the ORC power generation module. At the same time, depending on the application scenario, the condenser can be combined with a cooling water circulation system or an air-cooled system. In industrial systems and other scenarios with high requirements for cooling effect and sufficient water supply, a cooling water circulation system is used; in small systems or scenarios with relatively scarce water resources, an air-cooled system is used to ensure that the working fluid can be condensed efficiently and to provide a guarantee for the recycling of the working fluid.

[0065] The intelligent control module includes:

[0066] IoT controllers are used to monitor and adjust system operating parameters in real time.

[0067] The sensor array, including temperature and pressure sensors, is used for fault detection and protection switching.

[0068] It should be noted that when the compressor load increases and the power consumption of the control system increases, the working fluid flow rate and expander speed should be increased accordingly to improve the power generation. When the capacitor has sufficient power and the compressor load is small, the working fluid flow rate and expander speed should be appropriately reduced to avoid unnecessary energy consumption, thereby achieving a dynamic balance between power generation and power consumption and ensuring the stability and economy of the system's energy supply.

[0069] In addition, when the sensor group detects abnormal waste heat temperature that may affect the normal power generation of the ORC system, or when it detects an overload of the capacitor that may damage the capacitor and the entire system, the intelligent control module will immediately send a control signal to automatically switch the power supply of the compressor control system to an external power source. At the same time, it will trigger the alarm device to issue an audible and visual alarm signal to remind staff to check and maintain the system in a timely manner to ensure the safe and reliable operation of the system. Example 2

[0070] like Figure 4 , Figure 5 and Figure 6 As shown, a waste heat power generation control system for an electric scroll compressor includes the following steps:

[0071] Step S10: The compressor generates waste heat during operation, which is divided into waste heat from the casing, waste heat from the lubricating oil, and waste heat from the exhaust.

[0072] It should be noted that the waste heat generated by the electric scroll compressor during operation typically ranges from 70 to 120°C and mainly originates from the compressor casing, lubricating oil, and exhaust port.

[0073] Step S20: Waste heat is collected through the waste heat collection module, namely, the waste heat of the shell is absorbed by the phase change material, the waste heat of the lubricating oil is absorbed by the microchannel heat exchanger, and the waste heat of the exhaust port is absorbed by the spiral heat pipe.

[0074] Step S30: The temperature sensor detects whether the waste heat temperature of the three components has reached the set range. If it has not reached the set range, the external power supply is switched to power the controller. If it has reached the set range, the waste heat is transferred to the evaporator, where the waste heat evaporates the low-boiling-point mixed working fluid into gas, and the next step is performed.

[0075] In step S40, the gas generated by the evaporator drives the vortex collision generator to generate electricity, and then the electrical energy is directly supplied to the controller, capacitor and vehicle battery.

[0076] It should be noted that a low-boiling-point mixed working fluid is used. This mixed working fluid has a low boiling point and can fully evaporate within the temperature range of the waste heat received by the evaporator, absorbing a large amount of heat.

[0077] In detail, after the liquid low-boiling-point working fluid is transported to the evaporator, it undergoes full heat exchange with the waste heat from the compressor transferred from the waste heat collection module. During the heat exchange process, the liquid working fluid absorbs the energy of the waste heat, and its temperature gradually rises. When it reaches its boiling point, a phase change occurs, and it evaporates into high-temperature and high-pressure steam, which provides power for the subsequent generation of the vortex expander.

[0078] Step S50: Determine whether the capacitor is overloaded by the pressure sensor. If so, switch to external power supply to power the controller. Otherwise, repeat the determination step.

[0079] The following steps are included after step S40:

[0080] Step S41: After the evaporator absorbs the waste heat from the low-boiling-point mixed working fluid, the low-boiling-point mixed working fluid is transferred to the condenser to condense it into a liquid working fluid.

[0081] It should be noted that the air conditioning system of small electric vehicles usually adopts air cooling. The fan blows air across the heat exchange surface of the condenser to remove the heat of the working fluid vapor. Under the cooling effect of the condenser, the temperature of the low-pressure working fluid vapor after the work done by the vortex expander gradually decreases, releasing heat and eventually condensing into liquid working fluid.

[0082] Step S42: The liquid working fluid is pressurized from low pressure to the high pressure required by the evaporator by the working fluid pump, and then sent back into the evaporator.

[0083] It should be noted that the main function of the working fluid pump is to pressurize the low-pressure liquid working fluid condensed in the condenser from a low-pressure state to the high-pressure state required by the evaporator, so as to provide the necessary pressure conditions for the liquid working fluid to fully absorb waste heat and evaporate in the evaporator, and to ensure that the working fluid can achieve continuous circulation in the ORC system.

[0084] In detail, the working fluid pump is a variable frequency pump. The variable frequency pump can automatically adjust the pump's operating frequency and speed according to the temperature changes of the heat source received by the evaporator, thereby adjusting the flow rate of the working fluid. When the heat source temperature is high and the working fluid evaporates quickly, the pump speed is increased to increase the flow rate of the working fluid and ensure that there is sufficient working fluid in the evaporator.

[0085] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A waste heat power generation control system for an electric scroll compressor, characterized in that, include: Waste heat collection module, used to collect waste heat from the compressor casing, lubricating oil and exhaust port; ORC power generation module, used to convert waste heat into electrical energy; The intelligent control module is used to achieve dynamic balance between power generation and consumption and system protection.

2. The waste heat power generation control system for an electric scroll compressor according to claim 1, characterized in that, The waste heat collection module includes: A phase change material layer surrounds the compressor casing to absorb instantaneous high temperatures; Microchannel heat exchanger, integrated into the lubrication oil circuit; Spiral heat pipes are installed in the exhaust pipe.

3. The waste heat power generation control system for an electric scroll compressor according to claim 1, characterized in that, The ORC power generation module includes: An evaporator is used for the absorption and evaporation of a working fluid. The vortex expander generator has a permanent magnet on the moving plate and a stator coil on the stationary plate for direct power generation. Supercapacitors are used for energy storage and direct power supply. The condenser and the working fluid pump complete the working fluid circulation.

4. The waste heat power generation control system for an electric scroll compressor according to claim 1, characterized in that, The intelligent control module includes: IoT controllers are used to monitor and adjust system operating parameters in real time. The sensor array, including temperature and pressure sensors, is used for fault detection and protection switching.

5. The waste heat power generation control system for an electric scroll compressor according to claim 1, characterized in that, Includes the following steps: Step S10: The compressor generates waste heat during operation, which is divided into waste heat from the casing, waste heat from the lubricating oil, and waste heat from the exhaust. Step S20: Waste heat is collected through the waste heat collection module, namely, the waste heat of the shell is absorbed by the phase change material, the waste heat of the lubricating oil is absorbed by the microchannel heat exchanger, and the waste heat of the exhaust port is absorbed by the spiral heat pipe. Step S30: The temperature sensor detects whether the waste heat temperature of the three components has reached the set range. If it has not reached the set range, the external power supply is switched to power the controller. If it has reached the set range, the waste heat is transferred to the evaporator, where the waste heat evaporates the low-boiling-point mixed working fluid into gas, and the next step is performed. In step S40, the gas generated by the evaporator drives the vortex collision generator to generate electricity, and then the electrical energy is directly supplied to the controller, capacitor and vehicle battery. Step S50: Determine whether the capacitor is overloaded by the pressure sensor. If so, switch to external power supply to power the controller. Otherwise, repeat the determination step.

6. The waste heat power generation control system for an electric scroll compressor according to claim 5, characterized in that, The following steps are included after step S40: Step S41: After the evaporator absorbs the waste heat from the low-boiling-point mixed working fluid, the low-boiling-point mixed working fluid is transferred to the condenser to condense it into a liquid working fluid. Step S42: The liquid working fluid is pressurized from low pressure to the high pressure required by the evaporator by the working fluid pump, and then sent back into the evaporator.

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