Mechanical-cooling, free-cooling, and hybrid-cooling operation of a chiller
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Solution Overview
Problem
Conventional chiller systems are costly, have decreased performance, and are complex in terms of arrangement, installation, and maintenance due to their separate mechanical-cooling and free-cooling circuits, which limits their versatility and efficiency.
Innovation Solution
A chiller system that integrates mechanical-cooling and free-cooling circuits with a distribution header and control system to manage refrigerant flow through condenser coils, subcooler coils, and heat exchangers, allowing for hybrid-cooling operations and optimizing refrigerant flow based on ambient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate mechanical-cooling and free-cooling circuits are employed, then cooling functionality is provided, but manufacturing costs increase and device complexity increases
Solution Approach 1:
The patent combines separate mechanical-cooling and free-cooling circuits into a single integrated circuit that can operate in different modes. The system uses a common refrigerant loop with a compression device that can function as either a mechanical compressor or a free-cooling device depending on operating conditions, thereby reducing device complexity while maintaining cooling versatility.
Solution Approach 2:
The integrated circuit employs universal components that can serve multiple functions. The compression device can operate in mechanical-cooling mode during high ambient temperatures and switch to free-cooling mode during low ambient temperatures, allowing a single circuit to provide both cooling functionalities without requiring separate dedicated systems.
2Adaptability or versatility
If separate mechanical-cooling and free-cooling circuits are employed, then cooling functionality is provided, but manufacturing costs increase
Solution Approach 1:
The patent merges separate mechanical-cooling and free-cooling circuits into a single integrated circuit, reducing the total number of components required. This consolidation eliminates duplicate parts such as separate compressors, condensers, and expansion devices, thereby reducing manufacturing costs while maintaining the ability to provide both cooling functionalities.
Solution Approach 2:
The system uses universal components that can perform multiple functions. The compression device serves as both the mechanical compressor and the free-cooling device, and the condenser/evaporator components are shared between both cooling modes, reducing overall component count and manufacturing complexity.
3Adaptability or versatility
If separate mechanical-cooling and free-cooling circuits are employed, then cooling functionality is provided, but installation complexity increases
Solution Approach 1:
The patent integrates mechanical-cooling and free-cooling circuits into a single unified system, reducing the number of separate installations required. The integrated circuit uses common piping, shared components, and a unified control system, thereby simplifying installation procedures while maintaining both cooling functionalities.
4Adaptability or versatility
If separate mechanical-cooling and free-cooling circuits are employed, then cooling functionality is provided, but maintenance complexity increases
Solution Approach 1:
The patent combines separate mechanical-cooling and free-cooling circuits into a single integrated circuit, reducing the number of components that require maintenance. The unified system has fewer seals, valves, and moving parts compared to separate systems, thereby simplifying maintenance procedures and reducing maintenance 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
The integrated system reduces manufacturing costs, enhances performance, simplifies arrangements and installation, and reduces maintenance complexity while increasing versatility by enabling efficient operation across various cooling modes.
Implementation Method 1
an evaporator configured to place the working fluid in a heat exchange relationship with a conditioning fluid (e.g., water), such that the working fluid boils while absorbing heat from the conditioning fluid
Implementation Method 2
the working fluid boils while absorbing heat from the conditioning fluid
Implementation Method 3
a condenser having a coil configured to place the working fluid in a heat exchange relationship with a cooling fluid (e.g., water or air) that cools the working fluid in the condenser and causes the working fluid to condense into a liquid
Implementation Method 4
the working fluid may condense as the working fluid discharges heat to the cooling fluid in the condenser
Implementation Method 5
water used to cool the working fluid may be routed to a cooling tower that cools the water for subsequent return to the condenser
Implementation Method 6
a heat exchanger of the free-cooling circuit may receive the above-described conditioning fluid and a cooling fluid (e.g., the above-described cooling fluid including water or air, or a separate cooling fluid, such as glycol or a mixture of glycol and water), where the cooling fluid cools the conditioning fluid to adequate temperatures for delivery to the load
Data Source
AI summary
A chiller system includes a mechanical-cooling circuit configured to circulate a refrigerant through an evaporator of the mechanical-cooling circuit, where the evaporator is configured to cool a conditioning fluid with the refrigerant. The chiller system also includes a free-cooling circuit configured to circulate the refrigerant through a heat exchanger of the free-cooling circuit, where the heat exchanger is configured to cool the conditioning fluid with the refrigerant. The chiller system also includes a distribution header having a first inlet configured to receive the refrigerant from the mechanical-cooling circuit, a second inlet configured to receive the refrigerant from the free-cooling circuit, and an internal volume fluidly coupled to the first inlet and the second inlet. A fan coil unit of the chiller system is configured to receive the refrigerant from the internal volume of the distribution header.