Energy-saving controller for temperature feedback intelligent intermittent demisting control

Abstract

The invention discloses an energy-saving controller for temperature feedback intelligent intermittent demisting control, and belongs to the technical field of electric appliance engineering and intelligent control. The controller comprises a high-precision temperature sensing module, an intelligent control module, a heating wire driving module and an abnormal protection and alarm module. The intelligent control module dynamically controls the heating wire driving module to conduct on-off operation on the demisting heating wire according to temperature data, collected by the temperature sensing module in real time, of key parts of the refrigeration device through a preset temperature threshold interval and intermittent work cycle logic. The problems that in the prior art, due to the fact that a demisting heating wire is normally turned on, energy consumption is high, devices are prone to aging, and due to the fact that the demisting heating wire and a compressor are started and stopped at the same time, the demisting effect is poor in the high-humidity environment are solved, and efficient, energy-saving, safe and high-adaptability intelligent demisting control is achieved.

Description

Technical Field

[0001] This invention relates to the fields of electrical engineering and intelligent control technology, and in particular to a controller for refrigeration equipment that performs intermittent demisting based on temperature changes. Background Technology

[0002] During the operation of refrigeration units such as refrigerators, freezers, and commercial refrigerated display cases, components such as doors, frames, and beams are prone to fogging, condensation, and even icing due to temperature differences between the inside and outside and the ambient humidity. This not only affects the appearance of the equipment and the user experience, but long-term accumulation can also lead to component corrosion, short circuits in electrical components, and shorten the service life of the equipment. Currently, there are two main common defogging control solutions: one is that the defogging heating wire is constantly powered on and operates continuously. This solution has high energy consumption, and long-term high-temperature operation can easily lead to aging and breakage of the heating wire, posing a safety hazard; the other is that the defogging function starts and stops simultaneously with the compressor. This solution does not fully consider the impact of ambient humidity. In high-temperature and high-humidity areas (such as when the ambient humidity exceeds 75%), defogging is not timely, which can easily lead to condensation residue, water runoff, and even icing on the beam, failing to meet actual usage needs. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide an energy-saving controller for temperature feedback intelligent intermittent defogging control, so as to solve the technical problems of high energy consumption, easy aging of devices and poor defogging effect in high humidity environment in the prior art.

[0004] To solve the above-mentioned technical problems, the present invention provides the following technical solution: An energy-saving controller for intelligent intermittent defogging control with temperature feedback, characterized in that it includes a high-precision temperature sensing module for real-time acquisition of temperature data of key parts of the refrigeration device; an intelligent control module, communicatively connected to the high-precision temperature sensing module, for receiving the temperature data and outputting control commands according to a preset temperature threshold and intermittent operation control logic; and a heating wire drive module, connected to the intelligent control module and the defogging heating wire, for executing the on / off operation of the defogging heating wire according to the control commands. The intermittent operation control logic is as follows: when the temperature data is less than or equal to a preset temperature threshold, the defogging heating wire is controlled to operate for a first preset duration; when the temperature data is greater than the preset temperature threshold, the defogging heating wire is controlled to stop operating for a second preset duration.

[0005] Preferably, the temperature sensing module uses a thermistor sensor shared with the refrigeration system, with a measurement range of -40℃ to 85℃, a measurement accuracy of ±0.5℃, and a sampling frequency of not less than 1 time / second.

[0006] Preferably, the heating wire drive module uses a solid-state relay (SSR) as the switching element, with a response time ≤10ms.

[0007] Preferably, the preset temperature threshold is -5℃; the first preset duration is 30 to 50 minutes; and the second preset duration is 10 to 30 minutes.

[0008] Preferably, the control logic includes the following steps: The first step is to collect the temperature of key components; The second step is to determine whether the temperature is lower than the preset temperature threshold and continues to exceed the set duration Δt1. The third step is to start the heating program if the conditions are met, and first perform full-power heating for the first preset time. Fourth step, then switch to intermittent pulse heating mode, press "Start Δt" on / Close Δt off "Run in a loop;" Fifth step: When the temperature rises above the preset temperature threshold, stop heating and maintain it for the second preset time.

[0009] Preferably, Δt1 is 60 seconds, Δt on For 30 seconds, Δt off The time parameter is 90 seconds, and it can be customized by the user to adapt to the usage needs of different geographical regions and climates.

[0010] Preferably, the intelligent control module further includes anomaly protection logic, configured to: when the temperature data collected multiple times consecutively exceeds the preset temperature threshold, trigger the anomaly protection mechanism, cut off the power supply to the defogging heating wire, and issue an alarm signal.

[0011] Preferably, the "multiple consecutive samplings" refers to three consecutive samplings; the alarm signal includes sending a fault signal to the main control system of the refrigeration device and displaying a defogging abnormality code on the device display screen. After the alarm signal occurs, wait for 5 minutes before sampling again. When the temperature of the critical part is lower than the threshold, the alarm is lifted.

[0012] Compared with the prior art, the present invention has the following significant advantages: (1) By replacing continuous power supply with intermittent start-stop, energy consumption can be reduced by 20% to 40%; (2) The heating wire is avoided from running at high temperature for a long time, its service life is extended by 2 to 3 times, and the failure rate is reduced by more than 80%; (3) Dynamic periodic adjustment can still ensure 100% defogging compliance rate in high temperature and high humidity environment (humidity 75% to 95%), without condensation or icing; (4) Integrated abnormal protection logic can realize rapid power-off and fault alarm, and the system stability is improved by more than 50%; (5) It can share the sensor with the original temperature control system, and only the output terminal and corresponding program need to be added to the controller, which has low modification cost and is easy to promote and apply in various refrigeration devices. Attached Figure Description

[0013] Figure 1 This is a schematic diagram illustrating the system composition and functions of the controller of the present invention.

[0014] Figure 2 This is a flowchart of the intermittent defogging control logic of the controller of the present invention.

[0015] Figure 3 This is a flowchart of the abnormal protection logic of the controller of the present invention.

[0016] Figure 4 This is a schematic diagram of the external structure of the controller of the present invention.

[0017] Figure 5 This is a schematic diagram of the circuit component layout of the controller of the present invention.

[0018] In the attached diagram, 1 is the main board, 2 is the compressor relay, 3 is the output terminal, 4 is the temperature probe terminal, 5 is the transformer, 6 is the defrost relay, 7 is the fan relay, and 8 is the dew removal relay. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0020] refer to Figure 1During operation, this controller is initially powered by a 220V AC power supply. The power is purified and protected by the main fuse and filter circuit, and then multiple branch fuses provide tiered protection for different loads. The core of the controller is a high-precision temperature probe that sends temperature signals to the main control module. The main control module intelligently judges the situation based on set values ​​and real-time status, and drives the compressor, condenser / evaporator fan, solenoid valves, and lighting, while simultaneously controlling the defrosting auxiliary heating element via relays. Throughout the process, the controller continuously monitors the temperature status, immediately triggering protection and alarms in case of abnormalities, forming a closed-loop control system of "sensing-judgment-execution-feedback". This controller can automatically maintain a low temperature inside the cabinet, defrost periodically, and automatically shut down and alarm in case of overheating, achieving safe and efficient automated operation.

[0021] refer to Figure 2 The intermittent defogging logic of this controller enters an automatic cycle centered on real-time temperature monitoring after the system is started and parameters are initialized (temperature threshold set to -5℃, 40 minutes of operation, and 20 minutes of shutdown). The system continuously collects temperature data, and when the temperature is detected to be below or equal to -5℃, the heating wire is immediately activated and a 40-minute working timer is started, during which heating continues. Once the working time reaches 40 minutes or the system detects that the temperature has exceeded -5℃, the power supply to the heating wire is cut off, and a 20-minute shutdown intermittent phase begins. After the shutdown time ends, the system will unconditionally restart temperature collection and judgment, thus achieving energy-saving and efficient intelligent intermittent defogging in a continuous cycle.

[0022] refer to Figure 3 The abnormal protection logic of this controller continuously monitors temperature data once per second after startup. When the temperature collected by the system three times in a row is higher than the set threshold of -5℃, it will be immediately judged as an abnormal state and then execute protection actions within 1 second: forcibly cut off the power supply of the heating wire, lock the controller output, and send a fault signal to the main control system and trigger the alarm code on the display screen. The system then enters a locked waiting state and automatically resamples the temperature after 5 minutes of silence. The alarm will be lifted and the system will be reset only when the temperature is detected to return to -5℃ or below. Otherwise, it will remain in the locked protection state, thus forming a closed-loop safety protection mechanism with self-diagnosis and recovery capabilities.

[0023] refer to Figure 4 and 5This controller consists of an external plastic casing and internal electronic components. These components include: 1. Mainboard; 2. Compressor relay; 3. Output terminal; 4. Temperature probe terminal; 5. Transformer; 6. Defrost relay; 7. Fan relay; and 8. De-condensation relay. The core component of the high-precision temperature sensing module is the temperature probe terminal, which connects to an external thermistor sensor, introducing the physical temperature signal into the control system; it is the starting point of the entire temperature feedback chain. The core component of the intelligent control module and the anomaly protection and alarm module is the mainboard, whose internal program embeds "intermittent operation control logic" and "anomaly protection logic," serving as the computational and control core for intelligent decision-making and safety monitoring. The core component of the heating wire drive module is the de-condensation relay, which receives control commands from the mainboard and controls the power supply to the defogging heating wire through on / off operations; it is a physical switch for intermittent operation. The intersection of the heating wire drive module and the anomaly protection and alarm module is the output terminal. For the heating wire drive module, it provides the power connection point for the defogging heating wire. For the anomaly protection and alarm module, it provides a communication channel for sending fault signals to the main control system. The transformer provides a stable low-voltage power supply for the entire controller (especially the mainboard), serving as the energy foundation for system operation and supporting the normal operation of all modules. The compressor relay, defrost relay, and fan relay are controlled by the same mainboard, but are used to manage basic cooling functions such as refrigeration, defrosting, and fan circulation.

[0024] During actual operation, the temperature probe terminal continuously collects the door temperature signal and transmits it to the main board. The main board compares the received temperature with a preset threshold (e.g., -5℃) and runs an intermittent logic algorithm. Simultaneously, the main board manages the basic refrigeration cycle consisting of the compressor relay, defrost relay, and fan relay. If heating conditions are met, the main board sends a "close" command to the de-condensation relay, and current flows through the output terminal to the de-fogging heating wire, starting the working timer. Once the working time is reached or the temperature rises, the main board immediately "opens" the de-condensation relay, stopping the heating. Throughout the process, the transformer continuously provides clean, low-voltage electricity. If the main board continuously detects an anomaly based on temperature data (e.g., heating wire failure causing no temperature rise), it immediately triggers protection, locks the de-condensation relay output, and sends an alarm code to the host computer through the output terminal. The intermittent operation of the de-condensation relay is independent of the compressor relay's start-stop cycle, thus flexibly responding to high humidity environments and achieving the "dynamic cycle adjustment" described in the patent.

[0025] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An energy-saving controller for intelligent intermittent defogging control with temperature feedback, characterized in that, It includes a high-precision temperature sensing module for real-time acquisition of temperature data from key parts of the refrigeration device; and an intelligent control module, which is communicatively connected to the high-precision temperature sensing module, for receiving the temperature data and outputting control commands according to preset temperature thresholds and intermittent operation control logic. A heating wire drive module, connected to the intelligent control module and the defogging heating wire, is used to execute the on / off operation of the defogging heating wire according to the control command; The intermittent operation control logic is as follows: when the temperature data is less than or equal to a preset temperature threshold, the defogging heating wire is controlled to operate for a first preset duration. When the temperature data is greater than the preset temperature threshold, the defogging heating wire is controlled to stop working and remain for a second preset time.

2. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 1, characterized in that, The temperature sensing module uses a thermistor sensor shared with the refrigeration system, with a measurement range of -40℃ to 85℃, a measurement accuracy of ±0.5℃, and a sampling frequency of not less than 1 time / second.

3. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 1, characterized in that, The heating wire drive module uses a solid-state relay (SSR) as the switching element, with a response time of ≤10ms.

4. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 1, characterized in that, The preset temperature threshold is -5℃; the first preset duration is 30 to 50 minutes; and the second preset duration is 10 to 30 minutes.

5. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 1, characterized in that, The control logic includes the following steps: The first step is to collect the temperature of key components; The second step is to determine whether the temperature is lower than the preset temperature threshold and continues to exceed the set duration Δt1. The third step is to start the heating program if the conditions are met, and first perform full-power heating for the first preset time. Fourth step, then switch to intermittent pulse heating mode, press "Start Δt" on / Close Δt off "Run in a loop;" Fifth step: When the temperature rises above the preset temperature threshold, stop heating and maintain it for the second preset time.

6. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 5, characterized in that, The Δt1 is 60 seconds, Δt on For 30 seconds, Δt off The time parameter is 90 seconds, and it can be customized by the user to adapt to the usage needs of different geographical regions and climates.

7. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 1, characterized in that, The intelligent control module also includes anomaly protection logic, configured to: when the temperature data collected multiple times consecutively exceeds the preset temperature threshold, trigger the anomaly protection mechanism, cut off the power supply to the defogging heating wire, and issue an alarm signal.

8. The energy-saving controller for temperature feedback intelligent intermittent defogging control according to claim 7, characterized in that, The "multiple consecutive samplings" refers to three consecutive samplings. The alarm signal includes sending a fault signal to the main control system of the refrigeration unit and displaying a defogging abnormality code on the equipment display screen. After the alarm signal occurs, wait for 5 minutes before sampling again. When the temperature of the critical part is lower than the threshold, the alarm is lifted.

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