Chiller Head Pressure Control with Dynamic Setpoint Adjustment
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Solution Overview
Problem
Existing chiller systems face inefficiencies due to fixed Head Pressure Control setpoints, leading to unnecessary power consumption and reduced performance under varying load and ambient temperature conditions.
Innovation Solution
A chiller system with a control system that dynamically adjusts the Head Pressure Control setpoint based on ambient temperature and load, using a pre-determined algorithm to minimize combined compressor and fan power input, and employing a load balancing valve to manage pressure ratios and initiate additional compressors for increased capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed Head Pressure Control setpoint is used, then the control system is simple, but energy efficiency deteriorates under varying load and ambient temperature conditions
Solution Approach 1:
The patent implements dynamic adjustment of the Head Pressure Control setpoint based on real-time ambient temperature and load conditions. The control system continuously modifies the setpoint within a range (e.g., 25-45 PSI) rather than maintaining a fixed value, allowing the chiller to adapt to varying operating conditions and minimize power consumption at both compressor and fan.
Solution Approach 2:
The patent changes the operational parameters of the chiller system by adjusting the Head Pressure Control setpoint dynamically. By varying this critical parameter based on ambient temperature and load, the system optimizes energy efficiency without requiring complete system redesign, achieving reduced power consumption through parameter optimization.
2Use of energy by moving object
If the Head Pressure Control setpoint is adjusted dynamically, then energy efficiency improves, but control system complexity increases
Solution Approach 1:
The patent employs feedback mechanisms where sensors continuously monitor ambient temperature and system load conditions. This information feeds back to the control system, which automatically adjusts the Head Pressure Control setpoint accordingly. The feedback loop enables intelligent, adaptive control that improves energy efficiency without requiring complex manual intervention.
Solution Approach 2:
The control system performs self-adjustment based on pre-programmed algorithms and real-time sensor data. The system automatically determines the optimal Head Pressure Control setpoint without external intervention, reducing the need for complex user programming while achieving energy optimization through autonomous decision-making.
3Use of energy by moving object
If the compression ratio is reduced, then compressor efficiency improves, but additional pressure management components are required
Solution Approach 1:
The patent introduces a bypass valve as an intermediary component that allows excess refrigerant to bypass the compressor discharge line. This mediator enables pressure management by redirecting flow to maintain optimal compression ratio, improving compressor efficiency without requiring complete system redesign.
Solution Approach 2:
The patent segments the refrigerant flow path by creating a bypass route that divides the main flow into two paths: one through the normal compression cycle and another through the bypass valve. This segmentation allows independent control of compression ratio and pressure management, enabling efficiency improvements while managing system complexity through modular flow control.
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 approach optimizes energy efficiency and reduces power requirements by adjusting the Head Pressure Control setpoint to match changing conditions, ensuring efficient operation across a range of loads and temperatures, thereby minimizing energy consumption and operating costs.
Implementation Method 1
a condenser having an inlet connected with the compressor outlet and an outlet
Implementation Method 2
a condenser having an inlet connected with the compressor outlet and an outlet
Implementation Method 3
an evaporator having an inlet connected with the expansion valve outlet and an outlet connected with the compressor inlet
Implementation Method 4
an evaporator having an inlet connected with the expansion valve outlet and an outlet connected with the compressor inlet
Implementation Method 5
a plurality of compressors having inlets and outlets
Implementation Method 6
an expansion valve having an inlet and an outlet, the inlet being in fluid communication with the condenser outlet
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
A chiller system includes a compressor operable at a compressor speed between a first speed and a second speed to deliver a flow of compressed fluid to a manifold at a compressor pressure and a condenser in fluid communication with the manifold to receive the compressed fluid. A condenser fan is operable at a fan speed between a minimum fan speed and a maximum fan speed to direct a cooling flow to the condenser to cool the compressed fluid and an evaporator is positioned to receive the flow of compressed fluid and operable to cool a second fluid. A controller is operable at least partially in response to a measured temperature of the second fluid and a measured temperature of the cooling flow to determine a desired pressure and to vary the compressor speed and the fan speed such that the compressor pressure equals the desired pressure.