Control, diagnostics, and architecture for micro booster supermarket refrigeration architecture
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Solution Overview
Problem
Supermarket refrigeration systems face challenges in maintaining efficient operation due to complexity and the need for refrigerants with high global warming potential, particularly in low temperature operations, which complicates maintenance and energy efficiency.
Innovation Solution
A micro booster refrigeration system is introduced, featuring dual and medium temperature refrigeration cases, with a configuration that includes multiple compressors, condensers, evaporators, and a bypass valve, allowing for operation within different temperature ranges and simplifying maintenance through a system controller that identifies necessary maintenance and controls system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If distinct low and medium temperature compressors are used, then refrigeration cases can operate at different temperature ranges, but device complexity increases
Solution Approach 1:
The medium temperature compressor is designed to perform multiple functions: it can compress refrigerant from medium temperature evaporators directly, and also compress refrigerant from low temperature evaporators through the booster configuration. This multi-functionality eliminates the need for separate low and medium temperature compressors, reducing device complexity while maintaining adaptability across different temperature ranges
Solution Approach 2:
The refrigeration system is segmented into two functional loops: a medium temperature loop and a low temperature loop. The medium temperature loop operates independently with its own evaporators and the medium temperature compressor. The low temperature loop uses the medium temperature compressor as a booster, with low temperature evaporators discharging to the medium temperature compressor's suction side. This segmentation allows each loop to be optimized for its temperature range while sharing common components
2Ease of operation
If extensive piping is used to connect refrigeration cases and compressors, then refrigeration cases can be distributed in retail area, but device complexity and maintenance difficulty increase
Solution Approach 1:
The suction lines from multiple low temperature evaporators are merged into a common suction manifold that connects to the medium temperature compressor. Similarly, discharge lines from the medium temperature compressor and low temperature compressor are merged into a common discharge manifold connecting to the condenser. This merging reduces the number of separate piping runs and simplifies the overall layout
Solution Approach 2:
A common suction manifold acts as an intermediary component between the low temperature evaporators and the medium temperature compressor. This manifold collects refrigerant from multiple evaporators and distributes it to the compressor, simplifying the piping arrangement and reducing the need for individual dedicated piping runs from each evaporator to the compressor
3Reliability
If refrigerants with high global warming potential are used for low temperature operation, then refrigeration performance can be achieved, but harmful emissions increase
Solution Approach 1:
The system changes the operating parameters of the refrigerant by using different evaporation temperatures in different loops. The medium temperature loop operates at higher evaporation temperatures where low GWP refrigerants perform well. The low temperature loop, which discharges to the medium temperature compressor, operates at lower temperatures but still uses the same low GWP refrigerant. This parameter change allows achieving low temperature refrigeration performance while maintaining low environmental impact
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 reduces equipment and energy costs, minimizes emissions by using low-pressure refrigerants with lower global warming potential, and simplifies maintenance by operating at predictable pressures and temperatures, enhancing overall efficiency and reducing direct emissions.
Implementation Method 1
the low temperature compressor operates with a relatively high compression ratio because it needs to bring the refrigerant to a condensing pressure
Implementation Method 2
the condenser is operable to receive refrigerant from the at least one second compressor
Implementation Method 3
The first evaporator is operable to receive refrigerant from the condenser and discharge refrigerant to the first suction line
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A refrigeration system includes first and second compressors, a condenser, first and second evaporators, and a valve. The first compressor is fluidly connected to first suction and discharge lines. The second compressor is fluidly connected to second suction and discharge lines. The second suction line is fluidly connected to the first discharge line. The condenser receives refrigerant from the second compressor. The first evaporator receives refrigerant from the condenser and discharges refrigerant to the first suction line. The second evaporator receives refrigerant from the condenser and discharges refrigerant to the second suction line. The valve is disposed between the first evaporator and the first suction line. The first suction line receives refrigerant when the valve is in a first position. The second suction line receives refrigerant when the valve is in a second position. The first compressor is bypassed when the valve is in the second position.