Condenser Refrigerant Level Control Using a Mechanical Flow Valve
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Solution Overview
Problem
Existing chillers face control stability issues and high manufacturing costs due to the use of multiple sensors and complex controllers for maintaining the liquid refrigerant level in the condenser, which affects the reliability of the turbo chiller.
Innovation Solution
A chiller system with a flow rate adjusting device that mechanically controls the refrigerant flow by using a flow hole with an elongated shape and an opening and closing member, which adjusts the flow rate based on the liquid refrigerant level, eliminating the need for electronic sensors and control units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors and complex controllers are used to detect and adjust liquid refrigerant level, then the liquid refrigerant level can be monitored and adjusted, but control stability deteriorates and manufacturing cost increases
Solution Approach 1:
The expansion valve is designed to automatically adjust the liquid refrigerant level based on the level itself, without requiring external sensors or controllers. The valve mechanism responds directly to level changes, creating a self-regulating system that eliminates control stability issues associated with electronic feedback loops
Solution Approach 2:
The patent removes electronic sensors and complex control units from the system, retaining only the essential mechanical expansion valve for level adjustment. This extraction of unnecessary components simplifies the control system and eliminates sources of control instability while maintaining the core functionality of level monitoring and adjustment
2Measurement precision
If multiple sensors and complex controllers are used to detect and adjust liquid refrigerant level, then the liquid refrigerant level can be monitored and adjusted, but manufacturing cost increases
Solution Approach 1:
The patent eliminates expensive electronic sensors, control units, and associated wiring from the system, retaining only the mechanical expansion valve which is simpler and less costly to manufacture. This extraction of complex electronic components directly reduces manufacturing costs while preserving the essential level detection and adjustment functionality
Solution Approach 2:
The patent employs simple, inexpensive mechanical components rather than expensive electronic devices. The expansion valve and associated mechanical level indication system are far cheaper to manufacture and maintain compared to electronic sensor arrays and control systems, making the overall system more cost-effective
3Extent of automation
If electronic sensors and control units are used for refrigerant level control, then automated control is achieved, but device complexity increases
Solution Approach 1:
The expansion valve automatically responds to liquid refrigerant level changes through direct mechanical action, achieving automation without electronic components. The system self-regulates based on physical principles, eliminating the need for sensors, controllers, and complex control algorithms while maintaining automated level control functionality
Solution Approach 2:
The patent replaces complex electronic control systems with a simpler mechanical system. The expansion valve and associated mechanical level indication mechanism provide automated control through purely mechanical means, substituting electronic complexity with straightforward mechanical operation that is easier to manufacture and maintain
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 solution maintains a consistent liquid refrigerant level in the condenser, enhances control stability, and reduces costs by eliminating the need for electronic devices, while providing precise refrigerant flow rate control.
Implementation Method 1
a flow rate adjusting device 200 that controls a flow rate of the liquid refrigerant according to a level (H) of the liquid refrigerant collected in the inside of the condenser 120
Implementation Method 2
The heat between the refrigerant and the cooling water is exchanged in the inner portion of the condenser. The cooling water is heated in the course of passing through the condenser.
Implementation Method 3
The liquid refrigerant condensed in the inside of the evaporator and the condenser
Implementation Method 4
The heat between the refrigerant and the cold water may be exchanged in the inner portion of the evaporator. The cold water is cooled in the course of passing through the evaporator.
Implementation Method 5
The liquid refrigerant condensed in the inside of the evaporator and the condenser
Data Source
AI summary
A chiller system includes a compressor that compress refrigerant, a condenser that exchanges heat between the refrigerant and a cooling water discharged from the compressor, and a flow adjusting device that is provided to a refrigerant outlet side of the condenser and adjusts refrigerant amount in the inside of the condenser, the flow adjusting device includes, a main body portion that is communicated with a tubing of the outlet side of the condenser, a refrigerant supply tube that extends to the main body portion from the condenser and supplies the refrigerant in the inside of the condenser to the inside of the main body portion, and a flow hole that is formed on the main body portion and is selectively opened and closed according to refrigerant pressure which is input through the refrigerant supply tube.