Refrigeration Compressor Suction Valve for Variable Capacity Control
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Solution Overview
Problem
Existing refrigeration compressor systems face inefficiencies due to constant refrigeration capacity, leading to excessive refrigeration during low thermal loads, which causes ice formation, dehumidification, and reduced compressor lifespan, and existing solutions either increase start-ups, require complex control systems, or provide insufficient regulation of refrigerant flow.
Innovation Solution
A compressor with a solenoid valve system that adjusts refrigerant flow by moving a shutter to regulate the flow area, allowing for flexible reduction of refrigerant flow rate between 10% and 90% through the use of a control system to match thermal load requirements, reducing refrigeration capacity without subjecting the compressor to stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the refrigerating capacity of the compressor is constant, then the compressor can bring the environment to the desired temperature quickly during high thermal load, but it causes excessive refrigeration, ice formation, and dehumidification during low thermal load periods
Solution Approach 1:
The patent applies the dynamics principle by making the refrigerating capacity adjustable rather than constant. The compressor system can dynamically modify its refrigerating capacity by selectively closing suction channels of one or more pistons based on the actual thermal load requirements, allowing the system to adapt between high and low load conditions without causing harmful effects
Solution Approach 2:
The patent implements parameter changes by modifying the flow rate of refrigerating fluid input to the pistons. By using solenoid valves to close suction channels, the system changes the physical parameter of refrigerant flow rate, thereby adjusting the refrigerating capacity to match thermal load requirements and prevent ice formation and excessive dehumidification
2Object-affected harmful factors
If the compressor is switched off upon reaching the desired temperature and restarted when temperature exceeds a threshold, then the refrigeration capacity is reduced, but the number of start-ups per hour increases significantly, reducing compressor operating life
Solution Approach 1:
Instead of binary on/off operation, the patent implements dynamic capacity modulation by selectively closing suction channels of individual pistons. This allows the compressor to reduce its refrigerating capacity continuously rather than completely shutting down and restarting, thereby avoiding frequent start-ups and extending compressor life while still adapting to thermal load changes
3Adaptability or versatility
If multiple low-power compressors are used instead of a single high-power compressor, then the refrigeration capacity can be better matched to thermal load, but the starting cost and control system complexity increase
Solution Approach 1:
The patent applies segmentation by dividing a single high-power compressor into multiple independent piston units, each with its own suction channel controlled by a solenoid valve. This allows selective deactivation of individual pistons to match thermal load without requiring multiple separate compressor machines, simplifying the overall system while maintaining adaptability
Solution Approach 2:
The patent implements multi-functionality by enabling a single compressor body to operate in multiple capacity modes (100%, 66%, 33%, or 0% of full capacity) by selectively activating or deactivating individual piston suction channels. This provides the versatility of multiple compressors within a single unified system
4Productivity
If the suction channel of one piston is completely closed to reduce thermal load, then the refrigerating capacity is reduced by up to 50%, but this rough regulation is insufficient to optimize plant performance upon thermal load variation
Solution Approach 1:
The patent implements dynamic regulation by allowing selective and independent control of each piston's suction channel through individual solenoid valves. This enables fine-grained adjustment of refrigerating capacity in incremental steps (e.g., closing one of two pistons for 50% reduction, or one of three for 33% reduction) rather than rough binary control, optimizing plant performance across varying thermal loads
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 allows for reliable and efficient adjustment of refrigeration capacity based on thermal load, reducing energy consumption and maintaining compressor reliability by minimizing pressure and temperature fluctuations, thus optimizing refrigeration plant performance.
Implementation Method 1
A compressor (2) for a refrigerating plant, featuring a head (18a, 18b) and a bank of cylinders (12) arranged in the head (18a, 18b). Each cylinder (12) has a piston (13) that moves inside to compress a refrigerating fluid. The head (18a, 18b) includes a suction chamber (19) that receives the refrigerating fluid from a suction line (9) through an opening (24). A solenoid valve (25a, 25b) is arranged in the suction chamber (19) with a shutter (28, 128) that can move to regulate the flow area of the opening (24), thereby adjusting the refrigerant flow rate
Data Source
AI summary
A compressor for a refrigerating plant comprising at least one cylinder (12); at least one piston (13), which slides alternately inside the cylinder (12); at least one head (18a) provided with a suction chamber (19), connected to a suction line (9) of the plant (1) and to the cylinder (12) to supply the cylinder (12) with a refrigerating fluid, and with a suction valve (25a), configured to regulate the flow rate of refrigerating fluid; the suction valve (25a) is movable between a first position, wherein is defined a first flow area which allows the suction of a first flow rate of refrigerating fluid, and a second position wherein is defined a second flow area smaller than the first flow area which allows the suction of a second flow rate of refrigerating fluid lower than the first flow rate.