Heat exchanger with cooling structure

Abstract

The application relates to the technical field of industrial temperature control and intelligent control, and discloses a heat exchanger with a cooling structure, which comprises a bottom plate, a heat exchanger, a switching mechanism, a cooler and a control element; the switching mechanism is composed of a three-way electromagnetic valve I, a pipeline I, a pipeline II and a three-way electromagnetic valve II; the control element integrates five modules of data acquisition and preprocessing, dynamic threshold generation, double-mode intelligent decision, cooperation and safety protection, learning and optimization; temperature data are collected through a sensor, cooling intervention threshold values are dynamically calculated in combination with environmental temperature and heat exchanger load change rates after preprocessing, and a direct-through energy-saving mode and a cooling mode are switched; time sequence control is adopted to switch on and off the electromagnetic valve, fluid backflow and pressure impact are avoided, and the electromagnetic valve has a fault self-checking function; the learning and optimization module updates control parameters through a lightweight regression algorithm and performs adaptive optimization; the application can cool as required, reduce energy consumption, and improve the operation stability and the intelligent control level of the heat exchanger.

Description

Technical Field

[0001] This invention relates to the field of industrial temperature control and intelligent control technology, specifically to a heat exchanger with a cooling structure. Background Technology

[0002] In the field of industrial temperature control and thermal management, heat exchangers are widely used in various equipment for heat exchange and temperature control of high-temperature fluid media. Traditional heat exchange systems typically employ two operating modes: "direct output" or "full-time cooling." While the direct mode offers energy-saving advantages under lower heat loads, it struggles to guarantee stable output temperature under high-temperature conditions. However, existing devices still exhibit the following problems during use:

[0003] The cooling intervention strategy is singular and has poor adaptability: The cooling control of most existing heat exchangers relies on a fixed temperature threshold and cannot dynamically adjust the cooling intervention conditions according to changes in ambient temperature or real-time load fluctuations of the equipment. In hot environments, the cooler may start too early or too much, leading to increased energy consumption. In low-temperature environments or light-load conditions, a cooling intervention threshold that is too low may cause unnecessary cooling actions and affect system energy efficiency.

[0004] The lack of timing coordination during the switching process poses a safety hazard: some heat exchangers with bypass switching function do not have precise timing control of the on / off sequence of the solenoid valves when switching between direct mode and cooling mode, which can easily cause problems such as pressure surge, fluid backflow or instantaneous pipeline overload, affecting system stability and service life.

[0005] Lack of self-learning and optimization capabilities: The control parameters of existing equipment (such as the ambient temperature influence coefficient and load change rate coefficient) are mostly fixed values ​​at the factory and cannot be automatically adjusted according to historical operating data. After long-term operation, the control strategy may be mismatched with the actual working conditions, resulting in a decrease in temperature control accuracy or an increase in energy consumption.

[0006] Inadequate fault detection and protection mechanisms: Traditional devices lack systematic fault self-checking and safety protection logic when solenoid valves are stuck, coolers fail, or sensors malfunction. They often require manual troubleshooting, resulting in delayed response and the risk of equipment overheating or system interruption.

[0007] Therefore, there is an urgent need for a heat exchanger with a cooling structure that can dynamically adjust the cooling intervention threshold according to changes in ambient temperature and load, achieve safe and smooth switching between direct and cooling modes, and have data-driven self-learning optimization capabilities to improve system energy efficiency, temperature control accuracy and operational reliability. Summary of the Invention

[0008] This invention provides a heat exchanger with a cooling structure, which solves the problems in the above-mentioned background technology, such as fixed cooling intervention strategy, safety hazards in mode switching, lack of self-learning ability of control parameters, and imperfect fault protection mechanism.

[0009] The present invention provides the following technical solution: a heat exchanger with a cooling structure, comprising a base plate, a heat exchanger fixedly mounted on the top of the base plate, a switching mechanism provided at the outlet end of the heat exchanger, the switching mechanism comprising a three-way solenoid valve one installed at the outlet end of the heat exchanger, two other valve ports of the three-way solenoid valve one being fixedly mounted with pipe one and pipe two respectively, the other end of pipe two being fixedly mounted with a three-way solenoid valve two, a cooler and a control component also being fixedly mounted on the top of the base plate, the inlet end of the cooler being fixedly connected to the other end of pipe one, two valve ports of the three-way solenoid valve two being fixedly connected to the end of pipe two and the outlet end of the cooler respectively, and the other valve port of the three-way solenoid valve two being fixedly mounted with an outlet pipe.

[0010] Preferably, the control component 5 includes: a data acquisition and preprocessing module, a dynamic threshold generation module, a dual-mode intelligent decision-making module, a collaboration and security protection module, and a learning and optimization module.

[0011] The data acquisition and preprocessing module is electrically connected to the first temperature sensor at the outlet of the heat exchanger, the second temperature sensor at the outlet of the cooler, and the ambient temperature sensor. It is used to acquire the temperature of the fluid at the outlet of the heat exchanger, the temperature of the fluid at the outlet of the cooler, and the ambient temperature, and to preprocess the temperature to form a standardized input dataset.

[0012] The dynamic threshold generation module receives the ambient temperature and a preset basic cooling threshold from the data acquisition and preprocessing module, and embeds a threshold adaptive algorithm.

[0013] B201: Dynamically calculate the optimal cooling intervention threshold under the current operating conditions based on the ambient temperature and historical load data of the heat exchanger;

[0014] B202: The optimal cooling intervention threshold is equal to the basic cooling threshold plus the first adjustment amount plus the second adjustment amount. The first adjustment amount is proportional to the deviation of the ambient temperature from the standard ambient temperature, and the second adjustment amount is proportional to the load change rate of the heat exchanger per unit time.

[0015] The dual-mode intelligent decision-making module is connected to the dynamic threshold generation module and the data acquisition and preprocessing module. It receives the current heat exchanger outlet temperature and the dynamic threshold to execute judgment logic, and determines whether to start the cooler based on the difference between the cooler outlet fluid temperature and the target output temperature.

[0016] The collaboration and safety protection module is connected to the dual-mode intelligent decision-making module and is used to control the on / off sequence of the three-way solenoid valve one and solenoid valve two according to the timing during mode switching, and has built-in fault self-checking logic.

[0017] The learning and optimization module records the duration, temperature drop effect, and energy consumption data of each cooling action and stores them in a storage unit. It also uses a lightweight regression algorithm to periodically update the weight coefficients in the dynamic threshold generation module.

[0018] The present invention has the following beneficial effects:

[0019] 1. This invention uses a dynamic threshold generation module to calculate the optimal cooling intervention threshold in real time by combining the ambient temperature deviation and the load change rate of the heat exchanger. It abandons the traditional fixed threshold control mode and can automatically adjust the cooling start time according to the working conditions to avoid over-cooling or cooling lag. While ensuring stable output temperature, it reduces the energy consumption of the cooler and achieves cooling and high-efficiency energy saving.

[0020] 2. This invention uses a collaborative and safety protection module to precisely control the on / off sequence of three-way solenoid valve one and three-way solenoid valve two. During the switching between direct-flow energy-saving mode and cooling mode, the valve passage is switched first and then the fluid flow direction and cooler power are adjusted. This effectively prevents fluid backflow, pipeline pressure shock and instantaneous overload problems, and improves the operating stability of the heat exchanger and the service life of the components.

[0021] 3. This invention records the operation data of each cooling action through a learning and optimization module, and continuously updates the weight coefficients of ambient temperature and load change rate through a lightweight regression algorithm, so that the control parameters are automatically optimized as the equipment runs for a long time and the operating conditions change. This solves the problems of decreased temperature control accuracy and increased energy consumption caused by fixed parameters and mismatch between strategy and operating conditions in traditional equipment, and realizes full life cycle adaptive control.

[0022] 4. This invention uses multi-dimensional fault self-checking logic, including built-in solenoid valve action, cooler efficiency, and sensor consistency, to quickly identify fault types when abnormalities occur, and force a switch to a pass-through safety mode and output alarm signals to avoid risks such as equipment overheating and system interruption. It eliminates the need for frequent manual troubleshooting, reduces maintenance costs, and ensures continuous and stable operation in industrial scenarios. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0024] Figure 2 This is a schematic diagram of the heat exchanger outlet structure of the present invention;

[0025] Figure 3 This is a schematic diagram of the switching mechanism of the present invention;

[0026] Figure 4 This is a schematic diagram of the module structure of the control component of the present invention;

[0027] In the diagram: 1. Base plate; 2. Heat exchanger; 3. Switching mechanism; 31. Three-way solenoid valve one; 32. Pipe one; 33. Pipe two; 34. Three-way solenoid valve two; 4. Cooler; 5. Control components; 6. Outlet pipe. Detailed Implementation

[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The heat exchanger with a cooling structure involved in the present invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Please see Figures 1-3 The heat exchanger shown includes a base plate 1, which provides a support foundation for overall installation. A heat exchanger 2 is fixedly installed on the top of the base plate 1 for heat exchange of a fluid medium. A switching mechanism 3 is provided at the outlet end of the heat exchanger 2 to switch the flow path of the fluid medium according to temperature requirements. The switching mechanism 3 includes a three-way solenoid valve 31 installed at the outlet end of the heat exchanger 2 to control the flow direction of the fluid medium. The other two ports of the three-way solenoid valve 31 are respectively fixedly installed with pipe 32 and pipe 33. A three-way solenoid valve 34 is fixedly installed at the other end of pipe 33. A cooler 4 and a control unit are also fixedly installed on the top of the base plate 1. Component 5, the first pipe 32 is used to transport the fluid medium to the cooler 4 for cooling treatment, the second pipe 33 is used to transport the fluid medium to the third solenoid valve 34 for subsequent distribution, the third solenoid valve 34 is used to combine the fluid medium from the second pipe 33 and the cooler 4 and control the outlet flow direction, the control component 5 is used to control the coordinated operation of each component, the inlet end of the cooler 4 is fixedly connected to the other end of the first pipe 32, two of the valve ports of the third solenoid valve 34 are fixedly connected to the end of the second pipe 33 and the outlet end of the cooler 4 respectively, and the other valve port of the third solenoid valve 34 is fixedly installed with an outlet pipe 6 for outputting the finally treated fluid medium to an external pipeline.

[0030] During operation, the operator controls the heat exchanger 2 via the control unit 5 to perform heat exchange on the high-temperature fluid medium. The fluid medium flows out from the outlet of the heat exchanger 2 and enters the three-way solenoid valve 31. The control unit 5 then controls the opening and closing state of the three-way solenoid valve 31 according to the actual temperature of the fluid medium. When the fluid medium temperature is too high, the three-way solenoid valve 31 connects to the passage of pipe 32, and the fluid medium enters the cooler 4 through pipe 32 for cooling. The cooled fluid medium flows out from the outlet of the cooler 4 and enters the three-way solenoid valve 34, and then is discharged through the outlet pipe 6. When the fluid medium temperature is not higher than the preset threshold, the three-way solenoid valve 31 connects to the passage of pipe 33, and the fluid medium directly enters the three-way solenoid valve 34 through pipe 33, and then is discharged through the outlet pipe 6. This achieves on-demand cooling of the fluid medium output from the heat exchanger 2.

[0031] The software system of the control component 5 adopts a modular and layered architecture, such as... Figure 4 As shown, it includes: a data acquisition and preprocessing module, a dynamic threshold generation module, a dual-mode intelligent decision-making module, a collaboration and security protection module, and a learning and optimization module. Each module interacts with information through a standardized data interface to form a closed-loop control link of "acquisition-analysis-decision-protection-update".

[0032] Data acquisition and preprocessing module: Electrically connected to the first temperature sensor at the outlet of the heat exchanger, the second temperature sensor at the outlet of the cooler, and the ambient temperature sensor, it is used to acquire the temperature of the fluid at the outlet of the heat exchanger, the temperature of the fluid at the outlet of the cooler, and the ambient temperature, and to preprocess the temperature to form a standardized input dataset.

[0033] In this embodiment, the control unit 5 integrates a data acquisition and preprocessing module, which is electrically connected to external sensors and functional modules within the control unit 5 via signal lines; specifically, it includes:

[0034] A101: Sensor Deployment and Signal Access

[0035] A first temperature sensor is installed on the pipe wall at the outlet end of heat exchanger 2. The first temperature sensor is a PT100 platinum resistance thermometer with an accuracy of ±0.1℃, and is used to collect the fluid temperature output by heat exchanger 2. ;

[0036] A second temperature sensor is installed on the pipe wall at the outlet end of cooler 4. The second temperature sensor is of the same model as the first temperature sensor and is used to collect the temperature of the fluid medium after cooling in real time. ;

[0037] An ambient temperature sensor is installed near the air inlet of the base plate 1 to collect the ambient temperature around the equipment. The signal output terminals of the three sensors are connected to the analog input interface of the control unit 5 via shielded cables, and RC filter circuits are configured at the interfaces to suppress high-frequency interference.

[0038] A102: Data Sampling and Caching

[0039] The microprocessor inside the control unit 5 reads the voltage or current signals of the three sensors sequentially at a fixed sampling period, converts them into digital quantities through the built-in 16-bit ADC, and converts the digital quantities into temperature values ​​according to the scaling transformation formula of each sensor.

[0040] After each complete set of three data points is collected, it is stored in a first-in-first-out (FIFO) buffer queue with a queue depth of 10 sampling points for subsequent filtering processing in the preprocessing stage.

[0041] A103: Amplitude Limiting and Noise Reduction Processing

[0042] To eliminate abnormal spike noise caused by electromagnetic interference or sporadic sensor fluctuations, the preprocessing first performs amplitude limiting filtering on the latest temperature value of each sensor:

[0043] Set the maximum allowable deviation between two adjacent sample values. For example, for and , ,for , ;

[0044] Calculate the current sample value With effective filter value The absolute value of the difference is ;

[0045] like Then determine If the sampled value is valid, it will be sent to the next step of processing; if Then discard Effective filter value Replace the current sampled value and record it as a limiting replacement event.

[0046] A104: Moving Average Filtering

[0047] The temperature data, after being amplitude-limited, enters the moving average filtering stage to further suppress periodic noise and random disturbances, specifically including:

[0048] For each sensor, maintain a length of [length missing]. A sliding data window; each time a new valid temperature value is obtained... Store it at the end of the window and remove the old data from the window;

[0049] Calculate the current window Arithmetic mean of temperature values ,Will This serves as the filtered output value of the sensor at the current sampling moment.

[0050] A105: Normalization

[0051] To facilitate numerical calculations by the subsequent dual-mode intelligent decision-making module and dynamic threshold generation module, the preprocessing module linearly normalizes the filtered temperature values ​​to dimensionless values. The normalization formula for an interval includes:

[0052] For the outlet temperature of the heat exchanger Normalized value ,in Take -20℃ as the lowest possible medium temperature. Take 150℃ as the highest possible medium temperature;

[0053] For cooler outlet temperature Normalized value ,in Take -10℃, Take 80℃;

[0054] For ambient temperature Normalized value ,in Take -30℃, Take 60℃;

[0055] All normalized results are rounded to three decimal places. If the calculated value exceeds... The range is forcibly truncated to 0 or 1.

[0056] A106: Standardized Dataset Output

[0057] The preprocessing module normalizes the temperature values. , , and the corresponding original filter value , , The data is packaged into a standardized input dataset. The dataset is stored in the RAM of the controller 5 in the form of a structure and simultaneously sent to the dynamic threshold generation module and the dual-mode intelligent decision-making module through the internal data bus for subsequent cooling threshold calculation and switching path determination.

[0058] A107: Loops and Synchronization

[0059] The above A101 to A106 are executed in a loop with a period of 200ms. After each sampling is completed, the preprocessing sends a "data ready" interrupt signal to the dynamic threshold generation module to ensure the real-time performance of the temperature data and the synchronization and coordination between the modules.

[0060] The data acquisition and preprocessing module enables reliable acquisition, noise filtering, and dimension unification of the temperatures at the outlets of heat exchanger 2, cooler 4, and the ambient temperature, providing a standardized data foundation for subsequent cooling control decisions.

[0061] Dynamic threshold generation module: Receives the ambient temperature from the data acquisition and preprocessing module, a preset basic cooling threshold, and embeds a threshold adaptive algorithm.

[0062] In this embodiment, the control unit 5 is equipped with a dynamic threshold generation module, which is electrically connected to the data acquisition and preprocessing module. This module receives standardized ambient temperature data and system preset parameters, and calculates the optimal cooling intervention threshold in real time using a built-in adaptive algorithm. Specifically, it includes:

[0063] B201: Dynamically calculate the optimal cooling intervention threshold under the current operating conditions based on the ambient temperature and historical load data of the heat exchanger;

[0064] B2011: Parameter Initialization and Storage

[0065] The following parameters are preset in the storage unit of control component 5:

[0066] Base cooling threshold The target outlet temperature is set according to the design of heat exchanger 2;

[0067] Standard ambient temperature Take the engineering standard reference value of 25℃;

[0068] Experience weighting coefficient : Range of values The initial value was set to 0.3 to characterize the degree of influence of ambient temperature on cooling requirements;

[0069] Experience weighting coefficient : Range of values The initial value is set to 0.1 to characterize the impact of the load change rate on cooling demand.

[0070] Load sampling window time : Take 60 seconds to calculate the rate of change of load per unit time;

[0071] The above parameters are stored in EEPROM in a non-volatile manner to ensure that they are not lost when power is off, and to support online updates of subsequent learning modules.

[0072] B2012: Receive and parse preprocessed data

[0073] The dynamic threshold generation module reads a standardized input dataset from the data acquisition and preprocessing module at fixed intervals via the internal data bus, including:

[0074] Real-time ambient temperature filter value The actual temperature filter value of the fluid at the outlet of heat exchanger 2 Used to calculate the rate of change of load;

[0075] Simultaneously, the module obtains the current time from the real-time clock of control component 5 to record historical load data, specifically including:

[0076] Define load index The result can be calculated by combining the temperature difference between the inlet and outlet of heat exchanger 2 with the flow meter signal, or directly obtained from the power monitoring interface built into heat exchanger 2.

[0077] Maintain a length of A circular queue used to store the most recently... Load value at each sampling time ;

[0078] The first-order difference method is used to calculate the load change rate per unit time. :

[0079]

[0080] in The latest load value Let M be the oldest load value before the Mth sampling, and the denominator be the total time span. If there are fewer than M sampling points, then... Take 0 temporarily.

[0081] B202: The optimal cooling intervention threshold is equal to the basic cooling threshold plus the first adjustment amount plus the second adjustment amount. The first adjustment amount is proportional to the deviation of the ambient temperature from the standard ambient temperature, and the second adjustment amount is proportional to the load change rate of the heat exchanger per unit time.

[0082] B2021: Calculate the adjustment amount for ambient temperature deviation (first adjustment amount)

[0083] The dynamic threshold generation module calculates the deviation of the current ambient temperature from the standard ambient temperature. :

[0084]

[0085] The first adjustment amount is then calculated. ,in This represents the influence coefficient of ambient temperature, in this embodiment. A value of 0.3 (dimensionless) means that for every 1°C deviation of the ambient temperature from the standard value, the cooling intervention threshold will be adjusted by 0.3°C accordingly.

[0086] when hour, A positive value raises the base cooling threshold, meaning that in hot environments, higher output temperatures are allowed before cooling is activated to prevent the cooler from over-running; when hour, A negative threshold indicates a lower threshold, prompting earlier intervention in cooling to protect the equipment.

[0087] B2022: Calculate the load change rate adjustment (second adjustment).

[0088] The dynamic threshold generation module generates thresholds based on the load change rate. Calculate the second adjustment amount :

[0089]

[0090] in This represents the load change rate influence coefficient, in this embodiment. The value is set to 2.5 (dimensionless). This adjustment significantly increases the cooling intervention threshold when the heat load rises sharply, thereby activating cooler 4 earlier to prevent temperature overshoot; when the load decreases... A negative value lowers the cooling intervention threshold, reducing unnecessary cooling.

[0091] B2023: Calculating the optimal cooling intervention threshold

[0092] The dynamic threshold generation module will generate the base cooling threshold. With the first adjustment amount Second adjustment amount Adding them together yields the optimal cooling intervention threshold under the current operating conditions. :

[0093]

[0094] To ensure system security, the module is also equipped with... Upper and lower limits:

[0095] like Then let ,like To prevent cooling intervention from causing the equipment to overheat; if Then let ,like This prevents excessive cooling from causing energy waste.

[0096] Threshold Output and Update: The dynamic threshold generation module will calculate the optimal cooling intervention threshold. The data is stored in the designated register of the control unit 5 in floating-point form and simultaneously sent to the dual-mode intelligent decision-making module via the internal data bus. After each complete calculation, a "threshold update" flag is sent to the dual-mode intelligent decision-making module for the latter to use when determining the on / off path of the three-way solenoid valve 31.

[0097] Cyclic calculation and dynamic adaptation: The loop is executed at the frequency synchronized with the data acquisition cycle, whenever the ambient temperature or the rate of change of the heat exchanger outlet temperature changes. It then automatically adjusts to match the cooling intervention threshold with the current operating conditions and environmental conditions in real time, thus achieving dynamic adaptive control.

[0098] Dual-mode intelligent decision-making module: Connects the dynamic threshold generation module and the data acquisition and preprocessing module, receives the current heat exchanger outlet temperature and dynamic threshold to execute judgment logic, and determines whether to start the cooler based on the difference between the cooler outlet fluid temperature and the target output temperature.

[0099] In this embodiment, the control unit 5 also includes a dual-mode intelligent decision-making module, which is electrically connected to the dynamic threshold generation module and the data acquisition and preprocessing module, respectively, for receiving the current heat exchanger outlet temperature. Dynamic threshold Cooler outlet fluid temperature and the preset target output temperature And based on the embedded decision logic, it performs switching path judgment and starts / stops and intensity adjustment of cooler 4, specifically including:

[0100] C301: Read input data

[0101] At the start of each control cycle, the dual-mode intelligent decision-making module reads real-time data via its internal data bus.

[0102] Read from the data acquisition and preprocessing module: fluid temperature at the heat exchanger outlet. Cooler outlet fluid temperature Read the optimal cooling intervention threshold under the current operating conditions from the dynamic threshold generation module. ;

[0103] Read the preset target output temperature from the storage unit of control unit 5. , representing the upper limit of the final output fluid temperature expected by the user.

[0104] C302: Execute the judgment logic

[0105] The dual-mode intelligent decision-making module will and The comparison is used to determine the flow status of the three-way solenoid valve 31:

[0106] like If the current outlet fluid temperature of the heat exchanger is determined not to meet the cooling intervention conditions, there is no need to start the cooler 4. The module outputs the first control signal to the three-way solenoid valve 31 to connect the passage where the pipeline 33 is located. The fluid medium passes through the outlet of the heat exchanger 2, the three-way solenoid valve 31, the pipeline 33, and the three-way solenoid valve 34 and is directly discharged from the outlet pipe 6. The system operates in "direct-flow energy-saving mode", and the cooler 4 remains in standby or shutdown state.

[0107] like If the current outlet fluid temperature of the heat exchanger is determined to exceed the cooling intervention threshold, the cooler 4 needs to be started for cooling. The module outputs a second control signal to the three-way solenoid valve 31 to connect the passage where the pipeline 32 is located. The fluid medium enters the inlet of the cooler 4 through the outlet of the heat exchanger 2, the three-way solenoid valve 31, and the pipeline 32 for cooling.

[0108] C303: Determine whether to start the cooler based on the difference between the cooler outlet temperature and the target temperature.

[0109] When entering "on-demand cooling mode" (i.e.) When this occurs, the dual-mode intelligent decision-making module further executes internal adjustments to the cooler 4, as follows:

[0110] Calculate temperature deviation ,in This refers to the real-time temperature at the outlet of cooler 4. The target output temperature;

[0111] like (Right now ): This indicates that the outlet fluid temperature of cooler 4 has met or fallen below the target requirement. The module outputs a third control signal to cooler 4, causing its internal fan to run at the lowest power to maintain basic cooling capacity or stop further cooling.

[0112] like (Right now This indicates that the cooler outlet temperature has not met the standard and cooling needs to be strengthened. The module will adjust accordingly. The size of the cooling intensity is divided into several levels:

[0113] when At that time, a fourth control signal is output to make the cooler 4 operate at a low speed, such as the fan speed being 40% of the rated speed. The first deviation threshold;

[0114] when At that time, the fifth control signal is output to make the cooler 4 operate at a medium speed, such as 70% fan speed. This is the second deviation threshold;

[0115] when At that time, the sixth control signal is output to make the cooler 4 run at a high level, such as the fan speed of 100%.

[0116] C304: Path status of the two-way solenoid valve under coordinated control

[0117] Regardless of whether the straight-through mode or the cooling mode is selected, the outlet pipe 6 can smoothly discharge fluid. The dual-mode intelligent decision module simultaneously controls the opening and closing of the valve port of the three-way solenoid valve 34:

[0118] In the direct-flow energy-saving mode, the fluid enters the three-way solenoid valve 34 directly through the second pipe 33, outputting the seventh control signal, so that the three-way solenoid valve 34 connects the valve port of the second pipe 33 with the valve port of the outlet pipe 6, and at the same time closes the valve port connected to the outlet end of the cooler 4.

[0119] In cooling mode, after being processed by cooler 4, the fluid enters three-way solenoid valve 2 34 from its outlet end. The module outputs the eighth control signal, which connects the valve port at the outlet end of cooler 4 with the valve port at the outlet pipe 6, and at the same time closes the valve port connected to pipe 2 33.

[0120] The coordinated control is controlled by the timing logic inside the module: first, switch the three-way solenoid valve 2 34 to the target channel, and after a 50ms delay, switch the three-way solenoid valve 1 31 or start the cooler 4 to prevent fluid backflow.

[0121] C305: Status Feedback and Exception Handling

[0122] After each decision is executed, the dual-mode intelligent decision-making module will record the current operating mode (direct-flow energy-saving mode / cooling mode), cooler setting, and temperature deviation. The status information is stored in the status register of control component 5 for use by the learning and optimization module.

[0123] Built-in timer: If the temperature deviation is within 10 consecutive control cycles in cooling mode... Always greater than However, the outlet temperature of cooler 4 If there is no downward trend, it is determined that the cooler 4 is faulty or the refrigerant is insufficient. An alarm signal is output to the alarm interface of the control unit 5, and the three-way solenoid valve 31 is automatically switched to the straight-through mode.

[0124] Collaboration and safety protection module: Connected to the dual-mode intelligent decision-making module, it is used to control the on / off sequence of the three-way solenoid valve one and solenoid valve two according to the timing during mode switching, and has built-in fault self-checking logic;

[0125] In this embodiment, the control component 5 also includes a coordination and safety protection module. This module is electrically connected to the dual-mode intelligent decision-making module and is used to control the on / off sequence of the three-way solenoid valve 31 and the three-way solenoid valve 34 according to the timing during the cooling path switching process. It also has built-in fault self-checking logic.

[0126] D101: Receive switching command

[0127] The collaboration and security protection module monitors the mode switching instructions output by the dual-mode intelligent decision-making module in real time. The instructions include "switch to direct energy-saving mode" or "switch to cooling mode". When the current mode is detected to be inconsistent with the target mode, the timing switching process is initiated.

[0128] D102: Executes timing control to prevent pressure surges and backflow.

[0129] The module controls the on / off sequence of three-way solenoid valve 31 and three-way solenoid valve 34 according to a preset timing logic, specifically including:

[0130] D1021: Switch to direct-flow energy-saving mode (switch back from cooling mode to direct-flow mode):

[0131] First time sequence ( ): Output control signal to close the inlet valve of cooler 4, and keep the current state of three-way solenoid valve 31 unchanged;

[0132] Second time series ( ): Output control signal to disconnect the three-way solenoid valve 2 34 from the outlet end of the cooler 4, and at the same time connect the valve port of pipe 2 33 to the outlet pipe 6.

[0133] Third time series ( ): The output control signal causes the three-way solenoid valve 31 to switch to the path of the connecting pipe 33;

[0134] Fourth time series ( ): Output control signal to shut down the compressor or fan of cooler 4, completing the switching.

[0135] D1022: Switch to cooling mode (switch from pass-through mode to cooling mode):

[0136] First time sequence ( ): Output control signal to start cooler 4 for pre-cooling, and keep the current state of three-way solenoid valve 31 unchanged;

[0137] Second time series ( ): Output control signal to disconnect the three-way solenoid valve 2 34 from the pipeline 2 33, and at the same time connect the outlet end of cooler 4 to the valve port of outlet pipe 6;

[0138] Third time series ( ): The output control signal causes the three-way solenoid valve 31 to switch to the path of the connecting pipe 32;

[0139] Fourth time series ( ): Based on the cooling intensity level calculated by the dual-mode intelligent decision-making module, cooler 4 is adjusted to the target operating power to complete the switching.

[0140] D103: Execute fault self-test logic

[0141] The collaboration and security protection module performs a fault self-check once in each control cycle, specifically including:

[0142] Solenoid valve fault detection: After the three-way solenoid valve 1 (31) or the three-way solenoid valve 2 (34) receives a switching command... Inside, flow sensors or pressure sensors installed at each valve port detect whether the fluid is flowing in the expected direction. If the flow or pressure status is not consistent with the command, the corresponding solenoid valve is determined to be stuck or damaged, the fault code is recorded and an alarm signal is output.

[0143] Cooler fault detection: After the system has been running in on-demand cooling mode for more than 5 minutes, compare the temperature difference between the inlet and outlet of cooler 4. ;like If the condition is not met, cooler 4 is determined to be faulty and an alarm signal is output.

[0144] Sensor consistency test: Compare the difference between the ambient temperature sensor and the outlet temperature sensor of heat exchanger 2 in the shutdown state. If the difference exceeds 5°C, the sensor is determined to be damaged and a maintenance prompt is output.

[0145] D104: Execute fail-safe protection action

[0146] When the fault self-test logic determines that a serious fault has occurred, the collaboration and safety protection module automatically executes safety protection actions:

[0147] Force all solenoid valves to switch to straight-through mode to ensure that the fluid medium can be discharged directly through the bypass to avoid a complete system interruption;

[0148] If the fault involves cooler 4 and there is a risk of overheating, the module outputs a control signal to shut down the heating source of heat exchanger 2 or reduce its load.

[0149] The fault alarm information, including the fault code, the time of occurrence, and the current operating parameters, is sent to the host computer through the communication interface of the control unit 5, and the external indicator light is illuminated.

[0150] D105: Status Recording and Recovery Attempts

[0151] The coordination and safety protection module stores the timing execution record, fault self-test result and protection action of each switch into the non-volatile memory of the control unit 5. For recoverable faults (such as temporary jamming of the solenoid valve), the module automatically attempts to recover every 30 seconds. If it fails three times in a row, it locks the safety protection state and waits for manual intervention.

[0152] Through the above steps, the coordination and safety protection module realizes the time-sequence safe switching between the three-way solenoid valve 31 and the three-way solenoid valve 34, and has comprehensive fault self-checking and fault-tolerant protection capabilities, thereby improving the operation of the heat exchanger 2 and the cooler 4 under complex working conditions.

[0153] Learning and Optimization Module: Records the duration, temperature drop effect, and energy consumption data of each cooling action, stores them in the storage unit, and uses a lightweight regression algorithm to periodically update the weight coefficients in the dynamic threshold generation module.

[0154] E101: Define Cooling Action Event

[0155] The learning and optimization module defines a complete cooling action as: from the determination of the dual-mode intelligent decision-making module And output the second control signal (start cooling mode) to begin, until subsequent conditions are met. Furthermore, when cooler 4 switches back to direct mode, the module automatically identifies the start and end times of the cooling action by listening to the mode switching status signal output by the coordination and safety protection module.

[0156] E102: Collect and record cooling action data

[0157] After each cooling cycle, the learning and optimization module collects data from the registers of control unit 5 and the coordination and safety protection module, and stores it in the storage unit:

[0158] Cooling duration The time difference between the start and end of the cooling mode;

[0159] Temperature drop effect The difference between the average inlet temperature and the average outlet temperature of cooler 4, i.e. ,in and These are the filtered average temperatures at the heat exchanger outlet and the cooler outlet, respectively, during the cooling process.

[0160] Energy consumption data Energy consumption data obtained by integrating the current built into cooler 4;

[0161] Average ambient temperature The average value of the ambient temperature sensor readings during the cooling process;

[0162] The average rate of change of outlet temperature of the heat exchanger is the load change rate. The average value of the load change rate calculated during the cooling process;

[0163] Each record is accompanied by a timestamp (year / month / day / hour / minute / second), forming a historical dataset.

[0164] E103: Constructing a Lightweight Regression Model

[0165] The learning and optimization module internally embeds a lightweight linear regression model to fit the relationship between the energy consumption and temperature drop effect of cooling actions, and updates the weight coefficients accordingly. and The model input variable is the ambient temperature deviation. and load change rate The model output is the target energy consumption. The specific regression equations include:

[0166]

[0167] in For bias terms, and The coefficients to be regressed are derived from the actual energy consumption in historical data. Compared with model predictions The error between them is calculated using the least squares method or recursive least squares method. and Update.

[0168] E104: Mapping regression coefficients to weight coefficients and

[0169] The learning and optimization module periodically updates the regression coefficients, and then... and Mapped to the environmental temperature influence weighting coefficient in the dynamic threshold generation module Weighting coefficients for load change rate Specific mapping methods include:

[0170] set up The benchmark value and The benchmark value Calculate the adjustment coefficient ,in These are the initial regression coefficients specified at the factory. ,renew To prevent sudden changes in coefficients from causing control instability, a limit is set on the magnitude of each update: , If the limit is exceeded, the update will be performed according to the maximum allowed step size.

[0171] E105: Periodically update the weight coefficients of the dynamic threshold generation module.

[0172] The learning and optimization module transmits the updated data via the internal data bus. and The coefficients are written into the coefficient register of the dynamic threshold generation module, which then calculates the optimal cooling intervention threshold. At that time, automatically adopt the new and This value allows for adaptive optimization of the control strategy.

[0173] The update timing is determined by a configurable timer within the learning and optimization module: it can be set to update after every N cooling actions or after every M hours of operation. Before updating, the module will check whether the amount of historical data is sufficient; if not, the update will be postponed.

[0174] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "include," "contain," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0175] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A heat exchanger with a cooling structure, comprising a base plate (1), characterized in that: A heat exchanger (2) is fixedly installed on the top of the base plate (1). A switching mechanism (3) is provided at the outlet end of the heat exchanger (2). The switching mechanism (3) includes a three-way solenoid valve (31) installed at the outlet end of the heat exchanger (2). The other two valve ports of the three-way solenoid valve (31) are respectively fixedly installed with pipe (32) and pipe (33). The other end of the pipe (33) is fixedly installed with a three-way solenoid valve (34). A cooler (4) and a control component (5) are also fixedly installed on the top of the base plate (1). The inlet end of the cooler (4) is fixedly connected to the other end of the pipe (32). Two valve ports of the three-way solenoid valve (34) are respectively fixedly connected to the end of the pipe (33) and the outlet end of the cooler (4). The other valve port of the three-way solenoid valve (34) is fixedly installed with an outlet pipe (6).

2. A heat exchanger with a cooling structure according to claim 1, characterized in that, The control unit (5) includes a data acquisition and preprocessing module, a dynamic threshold generation module, a dual-mode intelligent decision-making module, a collaboration and security protection module, and a learning and optimization module. The data acquisition and preprocessing module is electrically connected to the first temperature sensor at the outlet of the heat exchanger, the second temperature sensor at the outlet of the cooler, and the ambient temperature sensor. It is used to acquire the temperature of the fluid at the outlet of the heat exchanger, the temperature of the fluid at the outlet of the cooler, and the ambient temperature, and to preprocess the temperature to form a standardized input dataset. The dynamic threshold generation module receives the ambient temperature and a preset basic cooling threshold from the data acquisition and preprocessing module, and embeds a threshold adaptive algorithm. B201: Dynamically calculate the optimal cooling intervention threshold under the current operating conditions based on the ambient temperature and historical load data of the heat exchanger; B202: The optimal cooling intervention threshold is equal to the basic cooling threshold plus the first adjustment amount plus the second adjustment amount. The first adjustment amount is proportional to the deviation of the ambient temperature from the standard ambient temperature, and the second adjustment amount is proportional to the load change rate of the heat exchanger per unit time. The dual-mode intelligent decision-making module is connected to the dynamic threshold generation module and the data acquisition and preprocessing module. It receives the current heat exchanger outlet temperature and the dynamic threshold to execute judgment logic, and determines whether to start the cooler based on the difference between the cooler outlet fluid temperature and the target output temperature. The collaboration and safety protection module is connected to the dual-mode intelligent decision-making module and is used to control the on / off sequence of the three-way solenoid valve one and solenoid valve two according to the timing during mode switching, and has built-in fault self-checking logic. The learning and optimization module records the duration, temperature drop effect, and energy consumption data of each cooling action and stores them in a storage unit. It also uses a lightweight regression algorithm to periodically update the weight coefficients in the dynamic threshold generation module.

3. A heat exchanger with a cooling structure according to claim 2, characterized in that: The data acquisition and preprocessing module includes: A PT100 platinum resistance thermometer is installed at the outlet of the heat exchanger as the first temperature sensor, a second temperature sensor of the same model is installed at the outlet of the cooler, and an ambient temperature sensor is installed at the air inlet of the base plate. The signals from three sensors are read with a fixed sampling period of 200ms, converted into digital quantities by an ADC, and stored in a FIFO buffer queue with a depth of 10 sampling points. Amplitude limiting filtering is performed on the latest temperature value of each sensor, and the maximum allowable deviation between two adjacent sampling values ​​is set; the maximum allowable deviation is 5°C for the first and second temperature sensors, and 2°C for the ambient temperature sensor; The temperature data after amplitude limiting enters the moving average filtering stage, and the arithmetic mean is calculated as the filtered output value. The filtered temperature values ​​are linearly normalized to the [0,1] interval to form a standardized input dataset. Among them, the normalized range of the heat exchanger outlet temperature is -20℃ to 150℃, the normalized range of the cooler outlet temperature is -10℃ to 80℃, and the normalized range of the ambient temperature is -30℃ to 60℃.

4. A heat exchanger with a cooling structure according to claim 2, characterized in that: The dynamic threshold generation module calculates the optimal cooling intervention threshold by including: Set the base cooling threshold Standard ambient temperature Ambient temperature influence coefficient and load change rate influence coefficient ; Calculate ambient temperature deviation The first adjustment amount is obtained. The maintenance length is The circular queue stores historical load data and calculates the load change rate per unit time. The second adjustment amount is obtained. Optimal cooling intervention threshold And set an upper limit. and lower limit Protect.

5. A heat exchanger with a cooling structure according to claim 2, characterized in that: The dual-mode intelligent decision-making module executes the following judgment logic: like The first control signal is output to the three-way solenoid valve 1, so that it connects to the passage where pipe 2 is located, and the system is in the direct-flow energy-saving mode. like The second control signal is output to the three-way solenoid valve, which connects to the passage where pipe one is located, and the system enters the cooling mode. Calculate temperature deviation in cooling mode. ,according to The size of the scale adjusts the operating level of the cooler, while controlling the flow state of the three-way solenoid valve 2, so that the fluid can be smoothly discharged through pipe 2 or the cooler outlet.

6. A heat exchanger with a cooling structure according to claim 2, characterized in that: The fault self-check logic executed by the collaboration and security protection module includes: When switching to the direct-flow energy-saving mode, sequentially close the cooler inlet valve, switch the three-way solenoid valve to pipe two, switch the three-way solenoid valve to pipe two, and turn off the cooler fan. When switching to cooling mode, start the cooler pre-cooling in sequence, switch the three-way solenoid valve 2 to the cooler outlet passage, switch the three-way solenoid valve 1 to connect to pipe 1, and adjust the cooler to the target power. The fault self-check includes solenoid valve operation status detection, cooler temperature difference detection, and sensor consistency detection, and will force a switch to direct mode and alarm in case of serious fault.

7. A heat exchanger with a cooling structure according to claim 6, characterized in that: The timing control of the coordination and security protection module includes: Switch to direct-flow energy-saving mode: First timing t=0ms closes the cooler inlet valve; Second timing t=50ms switches the three-way solenoid valve two to connect pipe two and the outlet pipe; Third timing t=100ms switches the three-way solenoid valve one to connect pipe two; Fourth timing t=150ms shuts off the cooler fan; Switch to cooling mode: First timing t=0ms starts the cooler pre-cooling; Second timing t=100ms switches the three-way solenoid valve two to connect the cooler outlet and the outlet pipe; Third timing t=150ms switches the three-way solenoid valve one to connect the pipe one; Fourth timing t=200ms adjusts the cooler to the target operating power.

8. A heat exchanger with a cooling structure according to claim 2, characterized in that: The learning and optimization module includes: Define a complete cooling action as from Activate cooling mode to The process of switching back to pass-through mode; Record the duration, temperature drop effect, energy consumption data, average ambient temperature, and average load change rate for each cooling action; Construct a lightweight linear regression model with ambient temperature deviation and load change rate as inputs and target energy consumption as output. The lightweight linear regression model is as follows: ; The weight coefficients in the dynamic threshold generation module are updated by mapping regression coefficients. and And set a limit on the magnitude of a single update.

9. A heat exchanger with a cooling structure according to claim 8, characterized in that: The mapping update includes: set up The benchmark value and The benchmark value ; Calculate the adjustment factor ,in , The initial regression coefficients as specified by the factory. and For the coefficients to be regressed, update ; The update timing can be set to update after every N cooldown actions or after every M hours of operation. Before updating, the system will check whether the amount of historical data is sufficient. If it is insufficient, the update will be postponed.

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