Condenser ice blockage dredging system with seal head auxiliary heating function

Abstract

The invention relates to the technical field of condensation heat exchange, and discloses an end socket auxiliary heating condenser ice blockage dredging system which comprises a condenser body, end sockets are arranged at the two ends of the condenser body respectively, an end socket auxiliary heating device is arranged in an inner cavity of at least one end socket, and a direct or indirect heat exchange relation is formed between the end socket auxiliary heating device and a refrigerant flowing through the end sockets. The temperature monitoring assembly is used for collecting the internal temperature of the seal head, the pressure difference monitoring assembly is used for detecting the pressure difference between an inlet and an outlet of the condenser, and the controller is electrically connected with the seal head auxiliary heating device, the temperature monitoring assembly and the pressure difference monitoring assembly. When it is detected that the inlet and outlet pressure difference of the condenser continuously exceeds the set threshold value and the internal temperature of the end socket is lower than the preset unfreezing temperature interval, it is judged that ice blockage exists, and an end socket auxiliary heating device is started. The condenser ice blockage dredging system with the seal head auxiliary heating function is high in heat efficiency, dredging speed and safety and free of equipment damage risks.

Description

Technical Field

[0001] This invention relates to the field of condensation heat exchange technology, specifically to a condenser ice blockage unblocking system with head-assisted heating. Background Technology

[0002] In the operation of refrigeration, air conditioning, or heat pump systems, shell-and-tube condensers are one of the core heat exchange components. Under low-temperature or high-humidity conditions, trace amounts of moisture in the refrigerant can easily condense and freeze at the end of the internal flow path or in low-temperature areas of the condenser, especially in the relatively enclosed end caps and their internal liquid collection chambers where flow disturbances are weak, gradually forming a solid ice blockage structure.

[0003] Once ice blockage forms, it will significantly increase the internal flow resistance of the condenser, causing refrigerant flow to be obstructed, which in turn will lead to an abnormal increase in system condensing pressure and a decrease in heat exchange performance. In severe cases, it may cause the compressor to overload or even shut down for protection, posing a threat to the safety and reliability of the system.

[0004] Currently, the industry standard for dealing with this type of ice blockage is external localized heating. This method typically involves operators using a hot air gun, blowtorch, or flexible electric blanket to heat the condenser casing for an extended period after the system has been shut down. This allows heat to be conducted through the metal casing to the interior, aiming to melt the ice blockage.

[0005] However, this method has significant drawbacks: First, external heating has low thermal efficiency, with a large amount of heat lost to the environment, resulting in a long unblocking process; second, uneven external heating can easily generate significant thermal stress in stress concentration areas such as the end cap and the weld connecting it to the cylinder, posing safety hazards such as shell deformation, weld damage, and refrigerant leakage; third, because the heat cannot be precisely applied to the core ice-blocked area inside the end cap, the unblocking effect is unstable, and repeated ice blockages are likely to occur; fourth, the entire process is highly dependent on manual experience, lacks effective condition monitoring and control methods, and makes it difficult to achieve safe, repeatable, and standardized operations. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of the above-mentioned technologies by providing a condenser ice blockage unblocking system with head-assisted heating, which has high thermal efficiency, fast unblocking speed, high safety, and no risk of equipment damage.

[0007] To achieve the above objectives, the condenser ice blockage clearing system with head-assisted heating designed in this invention includes a condenser body, which is a shell-and-tube condenser with heads at both ends. Each head has an internal cavity for refrigerant collection and distribution. At least one of the internal cavities of each head is equipped with a head-assisted heating device, which forms a direct or indirect heat exchange relationship with the refrigerant flowing through the head. The system also includes a temperature monitoring component for collecting the internal temperature of the head, a differential pressure monitoring component for measuring the pressure difference between the inlet and outlet of the differential pressure monitoring component, and a controller electrically connected to the head-assisted heating device, the temperature monitoring component, and the condenser. The controller receives temperature and differential pressure signals, and when the condenser is detected… When the pressure difference between the condenser inlet and outlet continuously exceeds the set threshold and the internal temperature of the end cap is lower than the preset thawing temperature range, ice blockage is detected, and the auxiliary heating device for the end cap is activated. By directly placing the auxiliary heating device inside the end cap where ice blockage is frequent, targeted heating of the core area of ​​ice blockage is achieved, completely solving the problems of long heat transfer paths and severe heat loss in traditional external heating methods, significantly improving thermal efficiency. At the same time, by combining the dual judgment logic of temperature signal and pressure difference signal, the state of ice blockage can be accurately identified, avoiding ineffective heating or missed detection of ice blockage caused by misjudgment of a single signal. This achieves automatic identification and heating activation of ice blockage, greatly reducing reliance on human experience and laying the foundation for standardized operations.

[0008] Preferably, the temperature monitoring component is located inside the end cap, which can collect real-time temperature data of the area where ice blockage occurs, avoiding the lag and deviation of traditional external temperature measurement, providing accurate temperature basis for ice blockage judgment and heating process control, ensuring the accuracy of ice blockage identification and the timeliness of heating adjustment, and reducing the risk of low unblocking efficiency or equipment damage caused by inaccurate temperature data.

[0009] Preferably, the controller dynamically adjusts the output power of the auxiliary heating device for the end cap based on the changes in internal temperature of the end cap and the pressure difference between the inlet and outlet of the condenser. Based on real-time feedback of the changes in internal temperature of the end cap and the pressure difference between the inlet and outlet of the condenser, the controller dynamically adapts the heating power to solve the problems of "insufficient heating (slow unblocking)" or "excessive heating (energy waste + equipment risk)" that exist in traditional fixed power heating. By precisely controlling the defrosting rate, the controller ensures efficient melting of ice blockage while avoiding local overheating caused by excessive power, thus balancing unblocking efficiency and equipment safety.

[0010] Preferably, when the internal temperature of the end cap reaches a preset safety upper limit, the controller automatically reduces or cuts off the heating power of the auxiliary heating device for the end cap. By establishing a safety protection mechanism for the heating power, excessive thermal stress in stress concentration areas such as the end cap and welds caused by overheating is effectively avoided. This reduces the safety hazards of shell deformation, weld damage, and refrigerant leakage from the root, significantly improves the reliability of system operation and equipment service life, and solves the core defect of traditional external heating without overheat protection.

[0011] Preferably, the auxiliary heating device for the condenser head includes at least one heating element. The heating element can be an electric heating tube, a flexible electric heating film, or other heating structures suitable for low-temperature environments. It can be flexibly selected according to the spatial dimensions of the condenser head, the type of refrigerant, and the actual operating conditions, avoiding the problem of insufficient adaptability of a single heating element, greatly improving the applicability of the system in different refrigeration, air conditioning, or heat pump systems, and ensuring the stable operation of the heating element under low-temperature conditions.

[0012] Preferably, the auxiliary heating device for the end cap includes several heating elements arranged in a coiled, arrayed, or partitioned manner. These heating elements can specifically cover different areas of the refrigerant collection cavity inside the end cap, achieving directional heating. This solves the problems of "poor uniformity and inadequate local heating" in traditional external heating, ensuring that areas prone to ice blockage receive sufficient heat. It also avoids incomplete unblocking and repeated ice blockage due to heating dead zones, thus improving the stability of the unblocking effect.

[0013] Preferably, the auxiliary heating device for the end cap is divided into multiple independently controlled heating zones. The controller adjusts the heating power of each heating zone according to the temperature feedback of different heating zones. The power is increased for zones with low temperature and severe ice blockage, and the power is reduced for zones with temperature close to the thawing range. This not only improves heating uniformity and avoids local overheating or underheating, but also further optimizes energy efficiency and reduces ineffective energy consumption. At the same time, it is suitable for the actual scenario where the degree of ice blockage is uneven in different areas inside the end cap.

[0014] Preferably, the controller is linked with the regulating mechanism in the condenser pipeline to change the fluid flow state during the defrosting process. On the one hand, it can accelerate the discharge of ice blockage dissolution products (melted water and refrigerant mixture), prevent residual substances from condensing again to form ice blockage, and solve the problem of "recurrence after unblocking" that can easily be caused by traditional heating alone. On the other hand, it can enhance fluid convection heat transfer, promote the uniform diffusion of heat released by the heating element, further improve the defrosting rate, and shorten the system downtime for maintenance.

[0015] Preferably, when the internal temperature of the end cap reaches a preset safety upper limit, the controller outputs an alarm signal, which can promptly remind staff to pay attention to the equipment status, facilitate quick troubleshooting of potential anomalies, avoid the expansion of safety risks caused by hidden equipment problems, and improve system maintainability. Staff can quickly locate problems through the alarm signal, reducing operation and maintenance costs.

[0016] Compared with the prior art, the present invention has the following advantages: 1. High thermal efficiency and fast unblocking speed: The present invention integrates the heating device inside the end cap, realizing targeted heating of the core area of ​​ice blockage. This avoids the problems of heat conduction through the metal shell, long transmission path, and serious heat loss in traditional external heating methods, which significantly improves energy utilization, greatly shortens ice blockage unblocking time, and reduces system downtime for maintenance. 2. High safety and no risk of equipment damage: Based on the closed-loop control strategy of the internal temperature of the end cap and the pressure difference between the inlet and outlet of the condenser, the drainage process can be completed automatically under controlled conditions. This effectively avoids the problem of excessive thermal stress at the end cap and weld caused by uneven heating in traditional external heating methods, reduces the risk of shell deformation, weld damage and refrigerant leakage, and improves the safety and reliability of system operation. 3. Stable unblocking effect and low recurrence rate: The targeted heating method ensures that the heat is precisely applied to the ice blockage area. Combined with dynamic power adjustment and optional fluid flow state adjustment, it can completely melt and remove the ice blockage, solving the problems of incomplete unblocking and easy recurrence of ice blockage in traditional methods. 4. High degree of standardization and intelligence: The system realizes automatic ice blockage identification, automatic heating and unblocking, and adaptive process control through the controller, which reduces the reliance on human experience and avoids the subjectivity and uncertainty of manual operation. It realizes the standardization and intelligence of ice blockage unblocking operation, which is convenient for promotion and application in refrigeration, air conditioning or heat pump systems of different scales and types, and has good engineering application prospects. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the condenser ice blockage clearing system with head auxiliary heating according to the present invention.

[0018] The components in the diagram are labeled as follows: 1. Condenser body; 2. End cap; 3. Auxiliary heating device for end cap; 4. Temperature monitoring component; 5. Differential pressure monitoring component. Detailed Implementation

[0019] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the invention.

[0020] Example 1 like Figure 1 As shown, a condenser ice blockage unblocking system with end cap auxiliary heating is applied to a shell-and-tube condenser in a small commercial air conditioner. It includes a condenser body 1, which is a shell-and-tube condenser with end caps 2 at both ends. The end caps 2 form cavities for refrigerant collection and distribution. An end cap auxiliary heating device 3 is provided in the internal cavity of one end cap 2. The end cap auxiliary heating device 3 includes several electric heating tubes arranged in a coiled manner to evenly cover the high-ice blockage area inside the end cap cavity and form a direct or indirect heat exchange relationship with the refrigerant flowing through the end cap.

[0021] This embodiment also includes a temperature monitoring component 4 for collecting the internal temperature of the end cap 2, a differential pressure monitoring component 5 for detecting the pressure difference between the inlet and outlet of the condenser, and a controller electrically connected to the auxiliary heating device 3, the temperature monitoring component 4, and the differential pressure monitoring component 5. The temperature monitoring component 4 is fixedly installed in the middle of the internal cavity of the end cap 2, collecting the internal temperature signal of the end cap 2 in real time and transmitting it to the controller. The differential pressure monitoring component 5 is a differential pressure transmitter, with its two detection interfaces connected to the inlet and outlet pipes of the condenser, respectively, to detect the pressure difference between the inlet and outlet and transmit the pressure difference signal to the controller. The controller is a PLC controller that receives the temperature signal and the differential pressure signal. When it detects that the pressure difference between the inlet and outlet of the condenser continuously exceeds a set threshold and the internal temperature of the end cap is lower than the preset thawing temperature range, it determines that ice blockage exists and starts the auxiliary heating device 3. In this embodiment, the set threshold can be: a differential pressure threshold of 0.3 MPa, a preset thawing temperature range of -10℃ to 0℃, and a preset safety upper limit temperature of 50℃.

[0022] When the air conditioning system is running, if the differential pressure monitoring component 5 detects that the differential pressure between the inlet and outlet of the condenser exceeds 0.3MPa for 3 consecutive minutes, and the temperature monitoring component 4 detects that the internal temperature of the end cap 2 is -5℃ (lower than the preset defrosting temperature range), the controller determines that there is ice blockage inside the end cap 2 and automatically starts the electric heating tube, with the initial output power set to 800W.

[0023] During the heating process, temperature monitoring component 4 provides real-time temperature signals, and differential pressure monitoring component 5 provides real-time differential pressure signals. When the internal temperature of end cap 2 reaches 0℃, the controller adjusts the output power of the electric heating element to 500W; when the differential pressure drops to 0.15MPa (indicating that the ice blockage has partially melted), the power is further adjusted to 300W. When the internal temperature of end cap 2 reaches 50℃, the controller immediately cuts off the power to the electric heating element and outputs an alarm signal via a buzzer. If the differential pressure continues to drop below 0.1MPa (indicating that the ice blockage is completely cleared), the controller records the parameters of this clearing process, and the system resumes normal operation.

[0024] Example 2 like Figure 1 As shown, a condenser ice blockage unblocking system with head-assisted heating is applied to the shell-and-tube condenser of a large heat pump water heating system. It includes a condenser body 1, which is a shell-and-tube condenser with heads 2 at both ends. The inside of the head 2 forms a cavity for refrigerant collection and distribution. Head-assisted heating devices 3 are arranged in the internal cavities of the head 2 at both ends. Each head-assisted heating device 3 is divided into 3 independently controlled heating zones. Each zone uses a flexible electric heating film as a heating element, which is arranged in an array and fixed to the inner wall of the head 2 to form a direct or indirect heat exchange relationship with the refrigerant flowing through the head.

[0025] In this embodiment, it also includes a temperature monitoring component 4 for collecting the internal temperature of the end cap, a differential pressure monitoring component 5 for detecting the pressure difference between the inlet and outlet of the condenser, and a controller that is electrically connected to the auxiliary heating device 3 of the end cap, the temperature monitoring component 4, and the differential pressure monitoring component 5.

[0026] Specifically, in this embodiment, each heating zone is equipped with a temperature monitoring component 4 to collect temperature signals from each zone.

[0027] The controller uses an industrial-grade microcontroller with preset differential pressure threshold of 0.5 MPa, preset defrosting temperature range of -8℃ to 2℃, and preset safe upper limit temperature of 45℃. The controller is electrically connected to all heating elements, temperature monitoring component 4, and differential pressure monitoring component 5, and is also linked to the electric throttle valve in the condenser piping.

[0028] When the system is running, if the differential pressure monitoring component 5 detects that the differential pressure between the condenser inlet and outlet exceeds 0.5 MPa for 5 consecutive minutes, and multiple temperature monitoring components 4 detect that the internal temperature of the end cap is below 2°C, the controller determines that ice blockage exists and activates the heating elements of the end caps at both ends. Based on the signals fed back by the temperature monitoring components 4 of each zone, the output power is set to 1000W for the zone with lower temperature (such as the zone below -5°C), and the output power is set to 600W for the zone with relatively higher temperature (between -5°C and 2°C).

[0029] Simultaneously, the controller adjusts the electric throttle valve every 30 seconds with a small amplitude switch, altering the fluid flow in the pipeline. During heating, when the temperature of a zone rises to 2°C, the power of that zone drops to 300W; when the pressure difference drops to 0.2MPa, the power of all zones is adjusted to 200W. When the temperature of any zone reaches 45°C, the controller reduces the power of that zone to 50W. If the temperature continues to rise, the power to that zone is cut off, and an alarm signal is output. When the pressure difference stabilizes below 0.15MPa, the controller shuts down all heating zones, the electric throttle valve returns to normal operation, and the ice blockage clearing process is completed.

[0030] In the above embodiment, the controller dynamically adjusts the output power of the auxiliary heating device 3 of the head according to the temperature change inside the head and the pressure difference between the inlet and outlet of the condenser. When the temperature inside the head 2 reaches the preset safety upper limit, the controller automatically reduces or cuts off the heating power of the auxiliary heating device 3 of the head.

[0031] In the above and other embodiments, the head auxiliary heating device 3 includes at least one heating element, which may be an electric heating tube, a flexible electric heating film, or other heating structures suitable for low-temperature environments. Similarly, the head auxiliary heating device 3 may include several heating elements, which may be arranged in a coiled, arrayed, or partitioned manner. By dividing the head auxiliary heating device 3 into multiple independently controlled heating zones, the controller adjusts the heating power of each heating zone according to the temperature feedback of different heating zones. Furthermore, the controller is linked with the regulating mechanism in the condenser pipeline to change the fluid flow state during the defrosting process.

[0032] This invention relates to a condenser ice blockage clearing system with head-assisted heating, which boasts high thermal efficiency and rapid clearing speed. By embedding the heating device inside the head 2, targeted heating of the core ice blockage area is achieved, avoiding the problems of traditional external heating methods where heat must be conducted through the metal shell, resulting in long transmission paths and significant heat loss. This significantly improves energy utilization, drastically shortens ice blockage clearing time, and reduces system downtime for maintenance. Furthermore, it offers high safety with no risk of equipment damage. Based on a closed-loop control strategy using the internal temperature of the head 2 and the pressure difference between the condenser inlet and outlet, the clearing process can be completed automatically under controlled conditions. This effectively avoids the problem of excessive thermal stress in the head 2 and welds caused by uneven heating in traditional external heating methods, reducing shell deformation and weld damage. This reduces the risk of refrigerant leakage and improves the safety and reliability of system operation; the unblocking effect is stable and not prone to recurrence: the targeted heating method ensures that heat is precisely applied to the ice blockage area, and with dynamic power adjustment and selectable fluid flow state adjustment, the ice blockage can be completely melted and discharged, solving the problems of incomplete unblocking and easy recurrence of ice blockage in traditional methods; high degree of standardization and intelligence: the system realizes automatic ice blockage identification, automatic heating and unblocking, and process adaptive control through the controller, reducing the dependence on human experience and avoiding the subjectivity and uncertainty of manual operation. It realizes the standardization and intelligence of ice blockage unblocking operation, which is convenient for promotion and application in refrigeration, air conditioning or heat pump systems of different scales and types, and has good engineering application prospects.

[0033] It should be noted that the above description of the technical solutions is exemplary, and this specification may be embodied in different forms and should not be construed as limiting it to the technical solutions set forth herein. Rather, providing these descriptions will ensure that the disclosure of this invention is thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Furthermore, the technical solutions of this invention are defined only by the scope of the claims.

[0034] The aspects disclosed in this specification and claims are merely examples, and therefore, this specification and claims are not limited to the details shown. In the foregoing description, detailed descriptions of relevant known functions or configurations have been omitted where it would unnecessarily obscure the focus of this specification and claims.

[0035] Finally, it should be noted that the above description is a further detailed explanation of the invention in conjunction with specific embodiments. It should not be considered that the specific implementation of the invention is limited to these descriptions. For those skilled in the art, any simple substitutions made without departing from the concept of the invention should be considered within the scope of protection of this invention. The above embodiments are merely representative examples of the invention. Obviously, the invention is not limited to the above embodiments and many variations are possible. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the invention should be considered within the scope of protection of this invention.

Claims

1. A condenser ice blockage unblocking system with head-assisted heating, comprising a condenser body (1), wherein the condenser body (1) is a shell-and-tube condenser, and both ends are respectively provided with heads (2), wherein the interior of the heads (2) forms a cavity for refrigerant collection and distribution, characterized in that: At least one of the end caps (2) has an auxiliary heating device (3) in its internal cavity, which forms a direct or indirect heat exchange relationship with the refrigerant flowing through the end cap. It also includes a temperature monitoring component (4) for collecting the internal temperature of the end cap and a differential pressure monitoring component (5) for detecting the pressure difference between the inlet and outlet of the condenser, and a controller that is electrically connected to the auxiliary heating device (3), the temperature monitoring component (4) and the differential pressure monitoring component (5). The controller receives temperature signals and differential pressure signals. When it detects that the pressure difference between the inlet and outlet of the condenser continuously exceeds a set threshold and the internal temperature of the end cap is lower than the preset thawing temperature range, it determines that there is ice blockage and starts the auxiliary heating device (3).

2. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: The temperature monitoring component (4) is disposed inside the head (2).

3. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: The controller dynamically adjusts the output power of the auxiliary heating device (3) of the head according to the temperature change inside the head and the pressure difference between the inlet and outlet of the condenser.

4. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: When the internal temperature of the end cap (2) reaches the preset safety upper limit, the controller automatically reduces or cuts off the heating power of the auxiliary heating device (3) of the end cap.

5. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: The head auxiliary heating device (3) includes at least one heating element, which may be an electric heating tube, a flexible electric heating film or other heating structure suitable for low temperature environments.

6. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: The head auxiliary heating device (3) includes several heating elements, which are arranged in a coiled, arrayed or partitioned manner.

7. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: The auxiliary heating device (3) for the end cap is divided into multiple independently controlled heating zones. The controller adjusts the heating power of each heating zone according to the temperature feedback of different heating zones.

8. The condenser ice blockage unblocking system with head auxiliary heating according to claim 1, characterized in that: The controller is linked to the regulating mechanism in the condenser pipeline to change the fluid flow state during the thawing process.

9. The condenser ice blockage unblocking system with head auxiliary heating according to claim 4, characterized in that: When the temperature inside the head (2) reaches the preset safety upper limit, the controller outputs an alarm signal.

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