Digital refrigeration controller with integrated module driven electronic expansion valve
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Solution Overview
Problem
Current refrigeration systems face challenges in accurately controlling refrigerant fluid superheat degree due to limitations in mechanical thermostatic valves and existing electronic expansion valves, which require additional hardware modules, energy storage, and complex installations, restricting their application and efficiency.
Innovation Solution
A compact, single-module digital refrigeration controller integrates temperature control, defrosting logic, and superheat control functions, using a PID algorithm to adjust the step motor electronic expansion valve, with an integrated Emergency Energy Storage System and Load Control System to manage power outages without external modules, simplifying installation and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical thermostatic valves are used for expansion, then the system structure is simple, but the superheat degree control accuracy is low and frequent adjustments are required
Solution Approach 1:
The patent replaces mechanical thermostatic valves with an electronic expansion valve actuated by a step motor, substituting mechanical adjustment mechanisms with an electronically controlled system that achieves precise superheat degree control through digital actuation signals
Solution Approach 2:
The patent implements continuous adjustment of the expansion valve opening degree through step motor control, enabling dynamic parameter changes in refrigerant flow rate to maintain optimal superheat degree under varying operating conditions
2Device complexity
If pulse valves are used for electronic expansion control, then the device complexity is reduced, but the control accuracy is reduced and water hammers occur
Solution Approach 1:
The patent employs periodic pulse signals to actuate the step motor, which converts these periodic electrical impulses into precise rotational movements, achieving both simplified control architecture and high positioning accuracy without water hammer effects
Solution Approach 2:
The patent replaces pulse valve mechanical opening/closing action with a step motor-driven electronic expansion valve, substituting abrupt mechanical movement with controlled rotational actuation that eliminates water hammer while maintaining control simplicity
3Measurement precision
If step motor electronic expansion valves are used, then the refrigerant fluid regulation is more uniform and continuous, but additional actuator devices are required increasing cost and volume
Solution Approach 1:
The patent merges the step motor actuator, control circuitry, and electronic expansion valve into an integrated assembly, combining multiple functional components into a single unit that reduces overall system volume and complexity while maintaining precise refrigerant fluid regulation
Solution Approach 2:
The integrated actuator device performs multiple functions including motor actuation, control signal processing, and valve positioning, enabling a single component to replace what would traditionally require separate dedicated actuator devices
4Device complexity
If step motor electronic expansion valves are used without power storage, then the device complexity is reduced, but the valve remains open during power shortages causing system damage
Solution Approach 1:
The patent implements a self-service emergency closure mechanism where the electronic expansion valve automatically closes upon detection of power failure through its integrated control circuitry, eliminating the need for external power storage devices while ensuring reliable valve closure for system protection
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 solution provides improved control of the refrigeration process, reduces energy consumption, and ensures the electronic expansion valve remains closed during power outages without external power modules, enhancing system efficiency and reliability while minimizing installation complexity and costs.
Implementation Method 1
step motor electronic expansion valve
Implementation Method 2
control of digital refrigeration devices and refrigerant fluid superheat degree with Proportional-Integral-Derivative (PID) feed back
Data Source
AI summary
A digital refrigeration controller (100) with integrated module driven Step Motor Electronic Expansion Valve. The digital refrigeration controller (100) comprises a System (200) with a Processing Unit (206) for management of the digital controller (100), Unit (206) being connected to Serial Communication Interface (202), Sensor Signal Conditioning System (203), Charge Control System (204), Human-Machine Interface (205), Power Supply Detection and Selection System (207), Backup Power Supply Charging System (208), Real Time Clock (209) and Step Motor Electronic Expansion Valve Drive System (210). System (200) comprises further the following elements: Power Supply (201), a Backup Power Supply (211) and a Current Monitor (212). In case of power outage, the different elements of the system interact to keep the step motor electronic expansion valve closed without the need of external modules.