Cool Drying Control Using Lowest Gas Temperature Feedback
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Solution Overview
Problem
Conventional cool drying methods for gases, such as compressed air, face inefficiencies due to heat exchanger heating up when the cooling circuit is switched off, leading to temperature and dew point peaks, and energy wastage, as they rely solely on evaporator pressure or temperature measurements for switching the cooling circuit on and off.
Innovation Solution
A method that measures the lowest gas temperature or dew point and switches off the cooling circuit when the decrease in these values is less than a preset value over a predetermined time, and keeps the circuit on if the dew point is above a maximum threshold, while also eliminating pressure differences before restarting to prevent compressor starting issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the cooling circuit is switched off based on evaporator pressure or temperature measurements, then energy consumption is reduced, but temperature and dew point peaks occur in the supplied gas
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the lowest gas temperature (LAT) and adjusts the cooling circuit operation accordingly. The control unit switches off the cooling circuit only when the decrease in LAT over a predetermined time interval is less than a preset value, ensuring temperature stability while optimizing energy consumption. This feedback mechanism prevents premature shutdown and avoids temperature peaks in the supplied gas.
Solution Approach 2:
The system uses the gas itself to provide feedback about its cooling state by measuring the lowest gas temperature directly. This self-service approach eliminates the need for separate temperature indicators and allows the system to automatically determine when the gas has reached sufficient cooling without external intervention, thereby maintaining reliability while reducing energy consumption.
2Use of energy by moving object
If the cooling circuit is switched off early to save energy, then energy consumption decreases, but the gas temperature and dew point are not sufficiently reduced
Solution Approach 1:
The patent replaces conventional mechanical temperature measurement methods (evaporator temperature or pressure measurements) with a direct gas temperature measurement system. By measuring the actual lowest gas temperature and using this as the control parameter, the system accurately determines when sufficient cooling has been achieved, preventing premature shutdown while optimizing energy consumption. This substitution ensures the gas reaches the required temperature reduction before the cooling circuit is switched off.
Solution Approach 2:
The invention changes the control parameter from evaporator temperature or pressure to the lowest gas temperature (LAT). This parameter change allows the system to directly monitor the actual cooling effect on the gas and make switching decisions based on the real temperature state of the gas rather than indirect indicators, thereby achieving optimal balance between energy consumption and temperature reduction.
3Reliability
If the cooling circuit operates continuously to maintain low gas temperature, then gas temperature stability is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic action by switching the cooling circuit on and off based on the measured lowest gas temperature and its rate of change. Instead of continuous operation, the cooling circuit is activated only when necessary to maintain temperature stability, and switched off when the decrease in LAT is insufficient. This periodic operation maintains temperature stability while significantly reducing energy consumption compared to continuous operation.
Solution Approach 2:
The system dynamically adjusts the cooling circuit operation based on real-time measurements of the lowest gas temperature and its rate of change. The control unit continuously evaluates whether to switch the cooling circuit on or off based on current temperature conditions, making the system adaptive rather than static. This dynamic approach optimizes the balance between temperature stability and energy consumption by operating the cooling circuit only when necessary.
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 approach optimizes energy savings by switching off the cooling circuit when the lowest gas temperature or dew point is almost reached, preventing premature shutdowns and ensuring efficient condensation, thereby reducing energy consumption and compressor load.
Implementation Method 1
by lowering the air or gas temperature in the evaporator, moisture in the air or gas will condense
Implementation Method 2
this gas is led through the secondary part of a heat exchanger, whose primary part is the evaporator of a cooling circuit
Data Source
AI summary
Method for cool drying gas containing water vapor, where a gas is led through a secondary part of a heat exchanger, whose primary part is an evaporator of a cooling circuit. The temperature or the dew point is measured in the environment of the place where, when cool drying, the temperature of the gas to be dried is the lowest. The above-mentioned method also has the step of switching off the cooling circuit when the decrease of the lowest measured gas temperature (LAT) or the dew point during a predetermined period of time amounts to less than a preset value (y).