Condenser Coil Water Mist Control to Prevent Compressor Slugging
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Solution Overview
Problem
Air conditioning systems face inefficiencies and maintenance challenges due to liquid slugging in compressors, where refrigerant returns in a mixed vapor and liquid state, potentially damaging the compressor, and require effective cooling and cleaning of condenser coils to optimize operation.
Innovation Solution
An apparatus and method involving a filter system with a microcontroller-controlled water delivery system, using ambient or chilled water to cool and clean air passing through condenser coils, ensuring minimal water collection and optimizing compressor efficiency by controlling water delivery based on temperature, humidity, and compressor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If refrigerant is compressed in vapor form and routed through the condenser, then heat is rejected to outside air and refrigerant is condensed to liquid, but liquid slugging occurs when refrigerant returns to compressor in mixed vapor and liquid state causing compressor damage
Solution Approach 1:
The patent applies preliminary action by pre-cooling the incoming air before it reaches the condenser coils. This pre-cooling action prepares the air to more effectively absorb heat from the refrigerant, ensuring complete condensation of refrigerant vapor to liquid before it returns to the compressor, thereby preventing liquid slugging and protecting compressor reliability.
Solution Approach 2:
The patent introduces pre-cooled air as an intermediary medium to facilitate heat transfer. This pre-cooled air acts as a mediator that absorbs heat from the refrigerant in the condenser coils, enabling efficient condensation of refrigerant vapor to liquid state before compressor intake, thus preventing harmful liquid slugging.
2Use of energy by moving object
If condenser coils are cleaned of dust and debris, then heat rejection efficiency is improved, but maintenance costs and labor are increased
Solution Approach 1:
The patent applies self-service by incorporating a water delivery system that automatically cleans the condenser coils during normal operation. The system uses water to wash away dust and debris from the coils, maintaining heat rejection efficiency without requiring manual intervention or separate maintenance activities, thereby reducing labor costs and operational disruption.
Solution Approach 2:
The patent ensures continuous cleaning action by delivering water to the condenser coils during operational cycles. This continuous or periodic cleaning action maintains optimal heat transfer surfaces throughout system operation, preventing performance degradation from dust accumulation without requiring periodic shutdowns for manual maintenance.
3Productivity
If water is delivered to filter apparatus to cool and clean condenser coils, then operating costs are reduced through improved efficiency, but water delivery control complexity is increased
Solution Approach 1:
The patent applies feedback control by using sensors to monitor conditions such as coil temperature, water flow rate, and system operational state. This feedback information is used by the control system to automatically adjust water delivery timing and quantity, optimizing cooling and cleaning effectiveness while preventing excessive water usage or improper delivery that could cause liquid slugging.
Solution Approach 2:
The patent implements dynamic water delivery control where the system adjusts water flow characteristics based on real-time operational conditions. The water delivery timing, duration, and intensity are dynamically modified according to system state, ensuring optimal performance across varying operating conditions while maintaining simple overall system architecture.
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 reduces operating costs by enhancing condenser efficiency, minimizing compressor usage, and lowering maintenance through effective cleaning of condenser fins, thereby preventing damage from liquid slugging and improving overall system performance.
Implementation Method 1
water delivery system to cool and clean air passing through condenser coils
Implementation Method 2
cleaning the outside air greatly lowers the maintenance costs of cleaning the condenser fins of collected dust and flying debris
Implementation Method 3
The refrigerant, now cold, passes through the evaporator coil which is located within the inside air duct. Hot indoor air forced past the evaporator is cooled
Implementation Method 4
the condenser which rejects heat to the outside air and condenses most of the refrigerant to a liquid
Implementation Method 5
rejects heat to the outside air
Data Source
AI summary
An apparatus and method to cool compressors, condensing coils, and similar devices. The compressor or condensing coil is cooled by the delivery of water, which may be ambient temperature or chilled. In one embodiment, the water is delivered to a mesh filter or screen via one or more mist spray nozzles. Water conduits may be integrated with the filter frame. The method to control the delivery of the water is designed to conserve water. The control circuit comprises a microcontroller device which contains programming that receives inputs, including but not limited to, outside ambient air temperature, condenser liquid line temperature, relative humidity and electric current, and uses said inputs to provide a stepwise level of control (“solenoid open time”) of water delivery commensurate with outside air temperature and relative humidity.