A/C Service Tool Controller for Automated Refrigerant Flow
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Solution Overview
Problem
Manual control of A/C service tools, such as manifold gauge sets, is time-consuming and requires significant technician attention, leading to lengthy maintenance and service tasks due to the need for frequent equipment setup and refrigerant flow management.
Innovation Solution
An automated A/C service tool controller that connects to A/C systems and tools via conduits, controlling power supply and refrigerant flow, using a processor, valves, pressure sensors, and a display to automate tasks like refrigerant recovery, vacuuming, and leak checking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of A/C service tools is used, then the technician can directly monitor and adjust the service process, but the time required for maintenance tasks increases significantly
Solution Approach 1:
The service tool controller automatically monitors and adjusts refrigerant flow, power supply, and system parameters without requiring continuous technician intervention. The system performs self-diagnosis and self-regulation, allowing the service process to run autonomously while reducing manual operational burden and task completion time
Solution Approach 2:
Manual mechanical control of valves and gauges is replaced with an automated electronic control system that uses processors, sensors, and electronic actuators to manage refrigerant flow and system parameters, eliminating the need for manual monitoring and adjustment
2Adaptability or versatility
If multiple A/C service tools are used for different tasks, then comprehensive service can be performed, but the setup time and equipment switching time increases
Solution Approach 1:
The service tool controller is designed as a universal platform that can perform multiple service functions including refrigerant recovery, vacuum pumping, leak detection, and system charging. The system interfaces with various service tools through standardized connections, allowing a single device to replace multiple specialized tools and eliminate repeated setup procedures
Solution Approach 2:
Multiple service tool functions are integrated into a single unified controller system. The controller combines refrigerant flow management, power supply control, pressure monitoring, and temperature sensing in one device, allowing technicians to perform diverse service tasks without switching between separate equipment
3Reliability
If manual monitoring of refrigerant flow is performed, then the technician can ensure proper flow control, but significant technician attention is required throughout the process
Solution Approach 1:
The system incorporates pressure sensors, temperature sensors, and flow meters that continuously monitor refrigerant conditions and provide real-time feedback to the controller. The controller automatically adjusts valve positions and system parameters based on this feedback to maintain optimal refrigerant flow, ensuring reliable control without requiring continuous technician monitoring
Solution Approach 2:
The refrigerant flow control system operates autonomously by continuously sensing system conditions and self-adjusting flow rates through electronic valve control. The system monitors its own performance and makes real-time corrections without external intervention, maintaining reliable flow control while freeing the technician from constant attention requirements
4Loss of time
If automated control of service tools is implemented, then the time required for maintenance tasks is reduced, but the device complexity increases
Solution Approach 1:
A single universal controller device integrates multiple functions including power supply management, refrigerant flow control, pressure monitoring, temperature sensing, and communication interfaces. This consolidation reduces the need for multiple separate control devices while providing comprehensive automated control capabilities
Solution Approach 2:
The controller serves as an intermediary between the technician and the complex service tool system. It provides a simplified user interface and automatically manages the complexity of coordinating multiple service tools, sensors, and actuators, allowing the technician to benefit from automated control without directly dealing with system complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces the time and effort required for maintenance tasks by automating the control of A/C service tools, allowing technicians to focus on other tasks while the controller manages power and refrigerant flow, optimizing the service process and increasing efficiency.
Implementation Method 1
a pressure sensor communicatively connected to the processor and configured to sense a pressure within the manifold
Data Source
AI summary
An apparatus for automated control of A/C service tools for use during A/C servicing tasks. The apparatus including hardware and software to run the automation programs, connectors to connect with the service tools to allow passage of vapors and liquids between the service tools and the A/C system, and power ports to plug the service tools into the apparatus so that it may control the power to the service tools. Further, the apparatus may include sensors and valves so that it might sense pressure within a system of connected service tools and the A/C system, and so that it might be able to control the flow of vapors and liquids between components of the system based on the automation programs and the readings from the sensors.