Free cooling system
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Solution Overview
Problem
Conventional cooling towers consume excess energy due to constant operation regardless of load fluctuations, such as outside air temperature and air conditioning equipment settings.
Innovation Solution
A free cooling system comprising multiple outdoor units with heat medium circuits, controllers, and communication units, where heat medium pumps, first heat exchangers, and load side heat exchangers are connected by pipes, allowing for load-dependent operation through load pipes and fine control via communication between units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cooling tower operates at constant capacity determined by maximum load, then it can meet peak cooling demands, but it consumes excessive energy when load is low
Solution Approach 1:
The system divides the cooling function into multiple independent outdoor units (first outdoor unit for free cooling, second outdoor unit for conventional cooling) that can operate independently or in combination. This segmentation allows the system to select only the necessary cooling capacity based on actual load conditions, avoiding the energy waste of running a single large cooling tower at partial load.
Solution Approach 2:
The control unit dynamically adjusts the operation mode between free cooling outdoor units and conventional cooling outdoor units based on real-time conditions such as ambient temperature and load requirements. When ambient temperature is suitable, free cooling units operate; when ambient temperature is high, conventional cooling units take over. This dynamic adjustment optimizes energy consumption while maintaining reliable cooling supply.
2Adaptability or versatility
If a single large cooling tower is used to meet maximum load, then peak demand is satisfied, but the system lacks flexibility for load fluctuations
Solution Approach 1:
Multiple outdoor units are deployed instead of a single large cooling tower. Each unit can be independently controlled to match the actual cooling load, providing flexibility for load fluctuations. The system can operate one or more units simultaneously depending on demand, achieving both adaptability and energy efficiency.
Solution Approach 2:
The outdoor units are designed with multi-functionality, capable of operating in both free cooling mode (using ambient air) and conventional cooling mode (using refrigeration cycle). This universal design allows the same hardware to adapt to different load conditions and environmental conditions, maximizing versatility while minimizing energy waste.
3Device complexity
If free cooling outdoor units operate independently without communication, then system complexity is reduced, but coordinated control for energy optimization is lost
Solution Approach 1:
Communication units in each outdoor unit exchange operational status and environmental data with the control unit and other outdoor units. The control unit receives feedback from temperature sensors and operational status, then adjusts the operation of individual units accordingly. This feedback mechanism enables coordinated control that optimizes energy consumption while maintaining simple individual unit structures.
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
Enables energy-saving by allowing for dynamic adjustment of free cooling outdoor units based on load conditions, optimizing energy usage.
Implementation Method 1
a heat medium pump 11, a first heat exchanger 12, and a heat source side of a second heat exchanger 13 are connected by pipes, and a heat medium circulates through the heat medium circuit
Implementation Method 2
a first heat exchanger 12, and a heat source side of a second heat exchanger 13 are connected by pipes, a heat medium circulating through the heat medium circuit
Data Source
AI summary
A free cooling system includes a plurality of free cooling outdoor units each including a heat medium circuit, a controller, and a communication unit, the heat medium circuit being configured by connecting a heat medium pump, a first heat exchanger, and a heat source side of a second heat exchanger by pipes, a heat medium circulating in the heat medium circuit, the controller configured to control the heat medium pump, and the communication units performing communication with each other, wherein the plurality of free cooling outdoor units are coupled with each other by a load pipe that allows a load heat medium to flow to or flow out from a load side of each second heat exchanger.