Climate control system with improved leak detector
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Solution Overview
Problem
Existing climate control systems face challenges in detecting refrigerant leaks effectively due to their inability to account for various orientations during installation, leading to inefficiencies and potential hazards.
Innovation Solution
The proposed solution involves a climate control system that includes a heat exchanger, a drain pan with strategically positioned refrigerant leak sensors, and control circuitry. The system is designed to detect refrigerant leaks by positioning the sensors at specific distances relative to the drain pan's planes, allowing for efficient detection and response to leaks across different orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If refrigerant leak sensors are installed in climate control systems, then refrigerant leak detection capability is improved, but the system becomes ineffective when installed in various orientations due to fixed sensor positioning
Solution Approach 1:
The sensor mounting bracket is designed to rotate about a longitudinal axis, allowing the sensor to dynamically adjust its orientation relative to the drain pan. This rotational capability enables the sensor to maintain proper positioning regardless of whether the drain pan is installed horizontally, vertically, or at intermediate angles, thus resolving the contradiction between reliable leak detection and installation flexibility
Solution Approach 2:
The solution introduces a rotational degree of freedom (another dimension of movement) to the sensor mounting mechanism. By adding this rotational capability about the longitudinal axis, the system transitions from fixed positional sensing to orientation-independent sensing, allowing effective refrigerant leak detection across multiple installation configurations
2Ease of manufacture
If existing leak detection concepts are used, then installation is simplified, but they are overdesigned and ineffective for various system orientations
Solution Approach 1:
The sensor mounting bracket incorporates a rotation mechanism that allows easy adjustment of sensor orientation during installation. This dynamic positioning capability maintains installation simplicity while ensuring detection effectiveness across various orientations, avoiding the overdesign problem of fixed-position sensors
3Measurement precision
If sensors are positioned close to the drain pan, then detection sensitivity is improved, but the system fails to account for orientation variations
Solution Approach 1:
The sensor is mounted on a rotatable bracket that maintains optimal sensing distance from the drain pan while allowing orientation adjustment. This dynamic positioning preserves measurement precision by keeping the sensor close to the drain pan, while simultaneously achieving orientation independence through rotational capability
Solution Approach 2:
By adding rotational freedom about the longitudinal axis, the system decouples the sensor's distance from the drain pan (maintaining precision) from its orientation (achieving versatility). This dimensional addition allows the sensor to remain proximity-optimized while adapting to any installation angle
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 enables reliable refrigerant leak detection and response, enhancing safety and efficiency by ensuring proper installation and operation across multiple orientations, thereby preventing property damage and occupant hazards.
Implementation Method 1
the heat exchanger being configured to exchange thermal energy between a conditioned airflow and the refrigerant fluid
Implementation Method 2
the refrigerant leak sensor detects refrigerant located outside the closed circuit
Data Source
AI summary
Examples of the present disclosure relate to climate control systems and air handler units with improved leak detection, along with method for installing these systems. In some examples, the climate control system comprises a heat exchanger configured to exchange thermal energy between a conditioned airflow and a refrigerant fluid; a drain pan arranged to collect condensate produced at the heat exchanger, the drain pan including one or more drains configured to route condensate out of the drain pan; a refrigerant leak sensor coupled to the drain pan and positioned above the one or more drains and configured to detect a refrigerant leak; and control circuitry operably coupled to the refrigerant leak sensor, the control circuitry configured to: receive a signal from the refrigerant leak sensor indicative of refrigerant located outside the closed circuit associated with the heat exchanger, and determine a refrigerant leak has occurred based on the signal.