Cooling Device Dual-Sensor Control for Compressor Energy Efficiency
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Solution Overview
Problem
Conventional cooling devices inefficiently operate the compressor and fail to maintain compartment temperature at desired levels due to reliance solely on compartment temperature sensors, leading to unnecessary compressor activation and energy wastage, as they do not consider evaporator temperature information for control.
Innovation Solution
A cooling device with a control method that utilizes both compartment and evaporator temperature sensors to adjust compressor and fan operations, employing a PID method and AI-based actor-critic algorithm to calculate operating frequencies and fan speeds, ensuring efficient cooling by actively monitoring evaporator temperature and adjusting evaporator set values based on cooling demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compressor is controlled solely based on compartment temperature sensors, then the compartment temperature can be maintained within cut-in/cut-out limits, but the compressor operates inefficiently with unnecessary activation and energy wastage
Solution Approach 1:
The control unit proactively monitors evaporator temperature in advance and predicts future compartment temperature trends. By detecting evaporator temperature changes before they significantly impact compartment temperature, the system can anticipate cooling needs and avoid unnecessary compressor start-stop cycles, thereby reducing energy consumption while maintaining reliable temperature control
Solution Approach 2:
The control method dynamically adjusts compressor operation by continuously integrating multiple temperature inputs (compartment and evaporator sensors) and using AI-based prediction algorithms. This dynamic control adapts to changing thermal conditions, optimizing compressor runtime based on actual cooling needs rather than fixed cut-in/cut-out thresholds, thus improving energy efficiency while maintaining temperature reliability
2Ease of operation
If the evaporator temperature sensor is used only for controlling the defrost process, then the defrost function is simplified, but the compressor works unnecessarily because evaporator temperature information is not taken directly as an input to the control method
Solution Approach 1:
The evaporator temperature sensor serves multiple functions simultaneously: it continues to control the defrost process as before, and now also provides critical input for optimizing compressor operation and predicting compartment temperature trends. This multi-functional use of the existing sensor enables energy efficiency improvements without adding hardware complexity or complicating the control logic
Solution Approach 2:
The control unit implements a feedback mechanism where evaporator temperature data is continuously fed into the AI-based prediction algorithm. This feedback loop allows the system to learn from evaporator temperature patterns and adjust compressor operation accordingly, reducing energy wastage while maintaining simple sensor-based control architecture
3Power
If the compressor is started when evaporator temperature is low enough, then the evaporator cooling capacity is maximized, but it takes time for the compartment temperature to decrease leading to delayed cooling response
Solution Approach 1:
The control unit performs preliminary assessment by monitoring evaporator temperature trends and predicting future compartment temperature behavior. Instead of reacting only when compartment temperature reaches cut-in threshold, the system anticipates cooling requirements based on evaporator performance, enabling proactive compressor control that reduces response time while maintaining adequate cooling capacity
Solution Approach 2:
The control method dynamically balances evaporator cooling capacity with compartment cooling response time by continuously adjusting compressor operation based on real-time temperature data from both sensors. The AI-based prediction algorithm optimizes the trade-off between maximizing evaporator capacity and ensuring timely compartment cooling, adapting to varying thermal loads and conditions
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 allows for effective and efficient operation of the compressor and fan, optimizing energy usage by dynamically adjusting fan speeds and evaporator set values, ensuring precise temperature control and energy savings.
Implementation Method 1
the refrigerant fluid reaches the evaporator, thus reducing the temperature of the evaporator. By means of the fan, the air cooling down around the evaporator is transferred into the compartment
Data Source
Figure 1
AI summary
The present invention relates to a cooling device (1) comprising at least one compartment (2) wherein the items to be cooled and/or frozen are loaded; a compressor (3) which provides the performance of the cooling cycle; at least one evaporator (4) which is disposed on the rear wall of the compartment (2) and which provides the cooling of the compartment (2); at least one fan (5) which provides the transfer of the air cooled down by the evaporator (4) into the compartment (2); at least one first temperature sensor (6) which detects the temperature in the compartment (2); at least one second temperature sensor (7) which is disposed on the evaporator (4) and which detects the temperature of the evaporator (4); and a control unit (8) which enables the compressor (3) to be operated depending on the information from the second temperature sensor (7) and enables the fan (5) to be operated depending on the information from the first temperature sensor (6).