Cooling system and automatic coolant-injection method for cooling system
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Solution Overview
Problem
The existing cooling systems for energy storage converters are complex and prone to coolant leakage and inefficiencies due to air entrapment and pressure fluctuations, requiring manual intervention and leading to reduced heat dissipation and increased maintenance costs.
Innovation Solution
A cooling system with a control unit that automatically injects and supplements coolant based on liquid level and pressure thresholds, using a circulation pump and three-way valves to manage coolant flow and pressure, ensuring efficient operation and minimizing manual maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual coolant injection is used, then the injection process can be controlled, but the operation complexity increases and coolant leakage risk rises
Solution Approach 1:
The system uses automatic control based on liquid level and pressure thresholds to perform coolant injection and supplementation without manual intervention. The control unit automatically activates the injection pump when the liquid level drops below the lower threshold or when pressure drops below the lower pressure threshold, and deactivates it when thresholds are met, enabling the system to service itself.
Solution Approach 2:
The system employs liquid level sensors and pressure sensors to continuously monitor the coolant tank and pipeline conditions. The control unit receives feedback from these sensors and automatically adjusts the injection pump operation accordingly, creating a closed-loop control system that maintains optimal coolant levels and pressure.
2Reliability
If circulation pump is turned on and off repeatedly to exhaust air, then heat dissipation efficiency is maintained, but the time required for coolant injection increases
Solution Approach 1:
The system performs preliminary air exhaust operation before starting coolant injection. The control unit activates the circulation pump to exhaust air from the pipeline before coolant is injected, ensuring that the pipeline is ready for efficient heat dissipation from the beginning of the injection process.
3Reliability
If manual coolant supplementation is performed, then coolant loss is compensated, but device operation is interrupted and utilization ratio decreases
Solution Approach 1:
The system uses pressure sensors to continuously monitor coolant pressure in the pipeline. When the pressure drops below the lower pressure threshold, the control unit automatically activates the injection pump to supplement coolant, maintaining optimal pressure without interrupting device operation. This closed-loop feedback control ensures continuous operation and high utilization ratio.
Solution Approach 2:
The system automatically detects coolant pressure drops and performs supplementation without manual intervention or device shutdown. The control unit monitors pressure levels and activates the injection pump as needed, enabling the system to maintain optimal coolant pressure and continue operating at full capacity.
4Adaptability or versatility
If tortuous pipe arrangement is used, then cooling system layout is flexible, but air exhaust becomes difficult and heat dissipation efficiency reduces
Solution Approach 1:
The system performs preliminary air exhaust operation before coolant injection by activating the circulation pump to circulate coolant through the tortuous pipes. This preliminary action removes air pockets from difficult-to-reach areas of the tortuous pipe arrangement, ensuring efficient heat dissipation is achieved from the start of operation.
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
The system simplifies coolant injection and supplementation processes, enhancing heat dissipation efficiency and device utilization while reducing maintenance costs and time.
Implementation Method 1
a liquid level sensor for detecting a liquid level of the coolant tank
Implementation Method 2
a circulation pump... the circulation pump forces the coolant to circulate in the liquid cooling pipeline when being turned on
Implementation Method 3
a heat exchanger; a converter... liquid cooling pipeline for connecting the heat exchanger with the converter
Implementation Method 4
an injection pump connected to the coolant tank, for injecting the coolant from the coolant tank into the liquid cooling pipeline when the injection pump is turned on
Data Source
AI summary
The disclosure discloses a cooling system and an automatic coolant injection method for the cooling system. The cooling system includes a heat exchanger; a converter; a liquid cooling pipeline; a coolant tank with a liquid-level sensor; an injection pump for injecting coolant from the coolant tank into the liquid cooling pipe; and a control unit. When liquid level of the coolant tank reaches an upper threshold, the injection pump injects coolant into the liquid cooling pipeline. When pressure of the coolant in the liquid cooling pipe reaches an upper static liquid pressure threshold, the control unit turns off the injection pump, and executes the turning-on and turning-off operations of the circulation pump with a preset circulation period. The circulation pump forces the coolant to circulate in the liquid cooling pipeline when being turned on.