Cascade Compressor Unit Design to Reduce Refrigerant Leakage Volume
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Solution Overview
Problem
Existing refrigeration systems face challenges in minimizing refrigerant leakage, particularly due to the vibration of compressors which can cause damage to the refrigerant circuit.
Innovation Solution
The compressor unit is configured with two separate refrigerant cycles, each with its own compressor and heat exchanger, along with a cascade heat exchanger for heat exchange between the two refrigerants. This configuration includes shutoff valves and a leakage detection sensor to quickly contain and shut off refrigerant flow in case of leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single refrigerant circuit is used with multiple compressors, then device complexity is reduced, but the volume of leaking refrigerant increases when damage occurs
Solution Approach 1:
The refrigerant circuit is divided into multiple independent loops, with each compressor having its own dedicated refrigerant circuit. This segmentation ensures that if one circuit suffers damage, the refrigerant leakage is confined to that specific loop, preventing system-wide leakage and reducing the total volume of lost refrigerant.
2Loss of substance
If refrigerant circuits are divided into separate loops, then refrigerant leakage volume is reduced, but device complexity increases
Solution Approach 1:
The system is segmented into independent refrigerant loops, each with its own compressor and associated components. This segmentation reduces refrigerant leakage volume by isolating potential failure points.
Solution Approach 2:
The cascade heat exchanger serves multiple functions: it acts as a condenser for one refrigerant and an evaporator for another, enabling heat transfer between different refrigerant loops. This multi-functionality reduces the need for separate heat exchange equipment in each loop, thereby reducing overall device complexity despite the segmented circuit design.
3Device complexity
If compressors are housed in a single case, then device complexity is reduced, but the reliability decreases when vibration causes damage
Solution Approach 1:
Compressors are housed in separate cases rather than a single common housing. This physical separation, combined with independent refrigerant circuits, ensures that vibration-induced damage or leakage from one compressor does not affect other compressors or their circuits, thereby improving overall system reliability.
4Use of energy by moving object
If a cascade heat exchanger is used for heat exchange between refrigerants, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The cascade heat exchanger is designed to perform multiple functions: it serves as a condenser for the high-temperature refrigerant and an evaporator for the low-temperature refrigerant simultaneously. This multi-functional design enables efficient heat transfer between refrigerants while avoiding the need for separate heat exchange equipment, thus improving energy efficiency without proportionally increasing device 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
This configuration effectively reduces the volume of leaking refrigerant by dividing the refrigerant circuit into two separate cycles, minimizing the spread of refrigerant in case of leakage, and allowing for quick detection and containment of leaks.
Implementation Method 1
The cascade heat exchanger executes heat exchange between the first refrigerant and the second refrigerant
Data Source
AI summary
A compressor unit includes a first case, a first compressor, a cascade heat exchanger, a second compressor, a first connecting port, and a second connecting port. The first compressor, the cascade heat exchanger, and a heat source heat exchanger accommodated in a second case constitute a first refrigerant cycle. The second compressor, the cascade heat exchanger, and a utilization heat exchanger accommodated in a third case constitute a second refrigerant cycle. The first connecting port is connected to the heat source heat exchanger via a first connection piping. The second connecting port is connected to the utilization heat exchanger via a second connection piping.