Combined chiller and free cooling system for operation at intermediate ambient temperature
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Solution Overview
Problem
Existing chiller systems require separate units for refrigerant-based cooling and free cooling, leading to inefficient heat transfer, idle resources, and increased risk of human error and system faults, especially when units are not designed to operate together.
Innovation Solution
A combined chiller/free cooling system with outdoor coils arranged in parallel and controlled by a system of valves and a controller, allowing for efficient operation in high, low, and intermediate temperature modes, ensuring full utilization of heat transfer resources and optimal cooling resource selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate chiller unit and free cooling unit are used, then cooling capacity is provided, but heat transfer area is inefficiently utilized with idle resources
Solution Approach 1:
The patent combines the chiller unit and free cooling unit into a single integrated system where the condenser and evaporator heat transfer areas are shared between refrigerant-based cooling and free cooling operations. This merging eliminates idle heat transfer resources and allows continuous utilization of the heat transfer area regardless of operating mode.
Solution Approach 2:
The heat transfer components (condenser and evaporator) are designed to serve multiple functions: they operate as refrigerant heat exchangers during chiller mode and as air-to-water heat exchangers during free cooling mode. This multi-functionality ensures that the same hardware resources are productively used in both operating scenarios.
2Adaptability or versatility
If separate chiller unit and free cooling unit are combined, then cooling functionality is provided, but system faults and downtimes increase due to human error
Solution Approach 1:
By integrating the control systems of the chiller and free cooling units into a single microcontroller, the patent eliminates coordination errors between separate units. The unified control architecture ensures proper sequencing and valve management, reducing the risk of system faults and unplanned downtimes.
Solution Approach 2:
The microcontroller continuously monitors ambient temperature and system operating parameters to automatically select and switch between chiller mode and free cooling mode. This closed-loop feedback control eliminates manual intervention errors and ensures reliable operation based on real-time conditions.
3Productivity
If separate chiller unit and free cooling unit are used, then cooling is provided, but device complexity increases
Solution Approach 1:
The patent merges the separate chiller and free cooling units into a single integrated system with shared heat transfer components and a unified control architecture. This consolidation reduces the number of independent systems, simplifies installation and configuration, and lowers overall system complexity while maintaining both cooling functionalities.
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 system maximizes the use of heat transfer resources, reduces energy waste, and minimizes system faults by seamlessly switching between refrigerant-based cooling and free cooling based on ambient conditions, enhancing overall cooling efficiency and reliability.
Implementation Method 1
outdoor coils arranged in parallel, such that a first-side inlet of each coil is in fluid communication with a first-side coolant line and a second-side outlet of each coil is in fluid communication with the same second-side coolant line
Implementation Method 2
transfer heat from the coolant to outdoor air
Implementation Method 3
A third valve may be positioned to regulate the flow of coolant from the second-side coolant line (on the side of the second set of coils) toward a water evaporator
Implementation Method 4
A fourth valve may be positioned to regulate a flow of coolant from the second-side coolant line (on the side of the first set of coils) to a water condenser
Data Source
AI summary
A system includes a first set of coils receive coolant from a first coolant line and provide the coolant to a second coolant line. A second set of coils receive coolant from a third coolant line and provide the coolant to a fourth coolant line. A first valve regulates flow of coolant between the first and third coolant line. A second valve regulates flow of coolant between the second and the fourth coolant lines. A third valve regulates flow of coolant between the fourth coolant line and a fifth coolant line coupled to a water evaporator and a three-way valve. The three-way valve regulates flow of coolant between the fifth coolant line, the third coolant line, and a coolant input line. A fourth valve regulates flow of coolant between the second coolant line and a water condenser. A controller adjusts the valves to operate in an intermediate temperature mode.