Chiller System Virtual Temperature Sensing to Reduce Sensor Complexity
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Solution Overview
Problem
In cooler systems where multiple units are connected in series, monitoring middle water temperature is challenging due to space constraints and high material costs associated with traditional water temperature sensors, leading to complex modifications and increased costs.
Innovation Solution
A cooler system that uses current sensors, water temperature sensors, and virtual temperature sensors to detect and adjust refrigeration capacities based on entering and leaving water temperatures, allowing for the acquisition and control of middle water temperatures without the need for physical sensors in the layout, thereby reducing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If water temperature sensors are arranged to monitor middle water temperature, then measurement precision is improved, but device complexity and material costs increase
Solution Approach 1:
The patent creates a virtual temperature sensor that copies the measurement function of a physical temperature sensor. By using existing temperature data from sensors at the inlet and outlet of the cooler system, along with current sensor data, the system calculates and generates a virtual temperature value that represents the middle water temperature without requiring a physical sensor to be installed in the middle section.
Solution Approach 2:
The patent introduces an intermediary calculation method that uses the relationship between temperature difference, refrigeration capacity, and working current to derive the middle water temperature. The formula Tmid = Tenter - (Tenter - Tleave) × (C1/C2) × (I1/I2) acts as an intermediary mechanism that translates easily measurable parameters (inlet/outlet temperatures, currents) into the desired middle temperature value without direct measurement.
2Measurement precision
If water temperature sensors are arranged to monitor middle water temperature, then measurement precision is improved, but manufacturing costs increase
Solution Approach 1:
The virtual temperature sensor copies the measurement functionality without requiring additional physical hardware installation. The system reuses existing temperature sensors at the inlet and outlet positions, along with current sensors, to generate the middle temperature value through calculation, thereby avoiding the need to purchase and install additional temperature sensors in the middle section.
Solution Approach 2:
The system uses its own existing components (inlet/outlet temperature sensors and current sensors) to provide the middle temperature measurement function. By leveraging data already collected by the system's sensors and processing it through the calculation formula, the system achieves middle temperature monitoring without requiring external additions or modifications to the physical layout.
3Measurement precision
If space is reserved for water temperature sensor arrangement, then measurement precision is improved, but area requirement increases
Solution Approach 1:
The virtual temperature sensor approach copies the measurement capability without requiring physical space for sensor installation in the middle section. The calculation-based method uses data from existing sensors located at the inlet and outlet, eliminating the need to reserve additional space in the middle water flow path for temperature sensor placement.
Solution Approach 2:
The patent transitions from a spatial approach (physically placing a sensor in the middle of the water flow path) to a computational approach (calculating the middle temperature using data from other dimensions/locations). By moving the measurement function from the spatial domain to the computational domain, the system avoids the need for additional physical space in the cooler system layout.
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
Enables efficient and cost-effective monitoring and control of middle water temperatures, balancing operating loads and improving system stability without the need for additional physical sensors, thus reducing material costs and layout modifications.
Implementation Method 1
a condensed water flow path, an aqueous medium in the condensed water flow path sequentially flowing through each of the cooler units; a cooling water flow path, an aqueous medium in the cooling water flow path sequentially flowing through each of the cooler units
Data Source
AI summary
A cooler system includes a plurality of cooler units; a condensed water flow path, an aqueous medium in the condensed water flow path sequentially flowing through each of the cooler units; a cooling water flow path, an aqueous medium in the cooling water flow path sequentially flowing through each of the cooler units in a flow direction opposite to a flow direction of the aqueous medium in the condensed water flow path; a plurality of current sensors used for detecting working currents of the cooler units; water temperature sensors used for detecting an entering water temperature and a leaving water temperature of the cooling water flow path; at least one virtual temperature sensor arranged between the cooler units and used for acquiring a middle water temperature between the cooler units; and a controller.