Chiller-Mounted Transformer and VSD for Medium-Voltage Space Savings
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Solution Overview
Problem
Chiller systems with medium/high voltage AC power sources require large, expensive components and complex safety measures due to high voltage, leading to space inefficiencies and increased costs, as well as limitations in maintenance due to electrocution risks, and existing solutions like multi-phase power cell transformers are costly and consume excessive space.
Innovation Solution
A liquid-filled medium/high voltage transformer integrated with a variable speed drive (VSD) and mounted on the chiller equipment, utilizing the chiller's cooling system to reduce the transformer's size and heat losses, eliminating the need for additional floor space and reducing component costs by using low-voltage electrical components directly connected to the medium/high-voltage distribution system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If medium/high voltage transformer is used for chiller systems, then current capacity requirements are reduced, but equipment costs and complexity increase due to sophisticated arc suppression, insulation, and safety characteristics
Solution Approach 1:
The system segments the voltage transformation function by using a medium/high voltage transformer that separates the high voltage input stage from the low voltage output stage. This allows the chiller system to interface with medium/high voltage mains while internal components operate at standard low voltages, reducing complexity of power semiconductors and control electronics.
Solution Approach 2:
The medium/high voltage transformer acts as an intermediary device between the medium/high voltage mains and the low voltage chiller system components. It provides galvanic isolation and voltage transformation, enabling the use of standard low voltage components while connecting to medium/high voltage distribution systems.
2Quantity of substance
If medium/high voltage transformer is used for chiller systems, then current capacity requirements are reduced, but equipment costs increase due to sophisticated arc suppression, insulation, and safety characteristics
Solution Approach 1:
The system divides the electrical system into high voltage and low voltage sections, allowing standard off-the-shelf low voltage components to be used for the chiller system while only the transformer needs to handle medium/high voltage, reducing overall equipment costs.
Solution Approach 2:
The transformer changes the voltage parameter from medium/high voltage at the input to low voltage at the output, enabling the use of cost-effective low voltage components throughout the chiller system while maintaining compatibility with medium/high voltage distribution infrastructure.
3Power
If floor mounted medium/high voltage drives are used, then voltage requirements are met, but floor area required increases to approximately 50 ft.2 to 100 ft.2
Solution Approach 1:
The transformer and VSD are merged into a single integrated unit mounted on the chiller equipment. This combination eliminates the need for separate floor-mounted drive equipment, reducing floor space requirements while maintaining medium/high voltage input capability through the integrated transformer.
Solution Approach 2:
The integrated unit performs multiple functions: the transformer provides voltage transformation from medium/high to low voltage, the VSD provides motor speed control, and the unit itself serves as a space-saving mounting solution on the chiller equipment, eliminating the need for separate dedicated drive floor space.
4Power
If multi-phase power cell transformers are used, then medium/high voltage requirements are met, but space consumption increases excessively and costs increase
Solution Approach 1:
The transformer and VSD are combined into a single integrated unit, eliminating the need for separate multi-phase power cell transformer assemblies. This integration significantly reduces the space required compared to traditional multi-cell transformer configurations.
Solution Approach 2:
The integrated transformer uses a different architectural approach than multi-phase power cell configurations, changing the physical layout and space requirements while maintaining the same electrical functionality of transforming medium/high voltage to low voltage for motor drive applications.
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 solution provides a compact, cost-effective refrigeration system with reduced floor space requirements, eliminating the need for separate transformers and conduits, and directly transferring heat losses into the chiller system, maintaining lower ambient temperatures and simplifying maintenance by integrating the transformer and VSD on the chiller.
Implementation Method 1
The cooling means may include a heat exchanger in which the liquid is cooled by circulating condenser water, chilled water or refrigerant from the chiller system.
Data Source
AI summary
The present invention is directed to a power transformer and VSD mounted on the chiller equipment. The transformer is preferably a liquid-filled transformer rated for medium/high voltage input, and at least two output low voltages, one voltage for the VSD and other power equipment, and another voltage for the control panel and control equipment. The placement of the power transformer on the chiller eliminates the need to allocate additional floor space for an auxiliary transformer or medium/high voltage VSD. The transformer also includes cooling means in the form of a heat exchanger in which the liquid is cooled by circulating condenser water, chilled water or refrigerant from the chiller system. The cooling means may also be connected to cooling coils connected to the VSD. The size of the power transformer is significantly reduced by the use of the chiller system to remove heat from the transformer while in operation, thereby maintaining the ambient temperature rise of the transformer within its rated operating temperature range. The transformer and VSD heat is discharged to the outside ambient eliminating additional cooling requirements for the equipment room.