Filtered Refrigerant Leak Sensing for Air Conditioner NDIR Sensors
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Solution Overview
Problem
Conventional air conditioner units face challenges in accurately detecting refrigerant leaks due to contamination of non-dispersive infrared (NDIR) gas sensors by dust, debris, pollen, and other contaminants, leading to reduced sensor lifespan and inaccurate measurements.
Innovation Solution
A gas sensing system for air conditioner units is designed with a housing that includes vent apertures to allow leaked refrigerant into a sensor enclosure, where a gas sensor can measure refrigerant concentration while being protected from contaminants, using a controller to regulate operation and implement corrective actions upon detecting leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If NDIR gas sensors are used for detecting refrigerant leaks, then gas concentration measurement capability is provided, but the sensors are susceptible to contamination and fouling by dust, debris, pollen, dander, and other contaminants which shortens sensor life and affects measurement accuracy
Solution Approach 1:
The housing is divided into a sensor enclosure that houses the gas sensor and separates it from the contaminated environment. This segmentation allows the sensor to remain protected while still enabling gas detection through controlled apertures.
Solution Approach 2:
The vent apertures act as intermediaries that allow refrigerant gas to pass into the sensor enclosure while blocking larger contaminants. The apertures serve as a filtering mechanism that mediates between the contaminated external environment and the protected sensor interior.
2Reliability
If a protective cover is provided over the gas sensors to prevent contamination, then sensor protection from contaminants is improved, but gas flow or diffusion toward the gas sensor is negatively affected resulting in inaccurate readings
Solution Approach 1:
The housing incorporates vent apertures that function as porous openings, allowing gas molecules to pass through while blocking larger particulate contaminants. This porous structure enables selective permeability that protects the sensor while maintaining gas flow.
Solution Approach 2:
The protective housing provides localized protection specifically at the sensor location while maintaining open vent apertures in specific areas to allow gas flow. The protection is not uniform but strategically applied where needed while preserving measurement capability.
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 provides accurate and resistant gas concentration measurements, extending sensor life and ensuring safe operation by effectively detecting refrigerant leaks and adjusting unit parameters as needed.
Implementation Method 1
a gas sensor positioned within the sensor enclosure for measuring a gas concentration of the leaked refrigerant within the sensor enclosure
Data Source
AI summary
A gas sensing system for an air conditioner unit is provided. The air conditioner unit includes a bulkhead that divides a cabinet into an indoor portion and an outdoor portion, and a compressor circulates refrigerant through a sealed system. An electrically protected housing is positioned within the indoor portion and defines a sensor enclosure for receiving a gas sensor for measuring a gas concentration of leaked refrigerant within the sensor enclosure. The housing includes vent apertures to permit leaked refrigerant to enter the sensor enclosure while the vent apertures are covered by filters to prevent contaminants from entering the sensor enclosure.