Frequency Converter Cooling Using Segmented Refrigerant Flow Control
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Solution Overview
Problem
Existing refrigeration and air conditioning systems using frequency converters face inefficiencies in cooling due to uniform cooling solutions, leading to over-cooling or under-cooling, which can cause condensate formation and reliability issues, and require excessive refrigerant flow and costly dedicated circuits.
Innovation Solution
A refrigeration plant with a cooling device that uses the same refrigerating fluid to cool the frequency converter, divided into two portions with adjustable flow rates and thermal exchange elements, regulated by solenoid valves and temperature sensors to optimize cooling based on component needs, minimizing fluid usage and avoiding condensate formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a uniform cooling device is used for the frequency converter, then the cooling structure is simple, but it causes over-cooling or under-cooling leading to condensate formation or high temperatures
Solution Approach 1:
The cooling device is divided into multiple independent cooling circuits, each equipped with its own flow control valve. This segmentation allows different regions of the frequency converter to be cooled independently according to their specific thermal requirements, preventing both over-cooling and under-cooling while maintaining reasonable structural complexity.
Solution Approach 2:
The cooling system incorporates flow control valves that can dynamically adjust the refrigerant flow rate to each cooling circuit based on real-time temperature conditions. This dynamic adjustment capability enables the system to adapt to varying thermal loads and operating conditions, ensuring optimal cooling performance and reliability.
2Reliability
If a dedicated refrigerating fluid supply circuit is used for the frequency converter, then the cooling reliability is improved, but the system cost and complexity increase excessively
Solution Approach 1:
The frequency converter cooling system is merged with the existing refrigerating or conditioning plant by using the same refrigerating fluid and integrating the cooling circuits into the plant's refrigerant circulation system. This combination eliminates the need for a separate dedicated fluid supply circuit, reducing system complexity and cost while maintaining cooling reliability through proper circuit design and flow control.
Solution Approach 2:
The refrigerating fluid circulation system serves multiple functions: it cools both the main refrigerating plant components and the frequency converter electronics. By making the refrigerant system universal, the patent avoids the need for separate cooling systems while ensuring reliable cooling for all components through the multi-functional refrigerant circulation network.
3Device complexity
If a constant quantity of refrigerating fluid is bled at the compressor inlet, then the frequency converter cooling is simplified, but the plant efficiency is reduced
Solution Approach 1:
Instead of bleeding a constant quantity of refrigerating fluid, the system uses flow control valves in each cooling circuit to dynamically regulate the refrigerant flow rate based on the actual cooling needs of the frequency converter. This dynamic control ensures that refrigerant is only diverted when and where needed, maintaining plant efficiency while providing effective converter cooling.
Solution Approach 2:
The cooling system provides localized cooling to specific regions of the frequency converter that require it, rather than uniformly cooling the entire system. By directing refrigerant flow only to areas with thermal demands and controlling the flow rate locally, the system avoids unnecessary refrigerant diversion that would reduce plant efficiency while still achieving effective converter cooling.
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 solution enhances cooling efficiency, reduces energy consumption, and improves the reliability of frequency converters by accurately controlling temperature and minimizing refrigerant flow, achieving approximately 1% of the average flow rate only when needed, thus increasing overall system efficiency and economic benefits.
Implementation Method 1
a cooling device (13), supplied with a refrigerating fluid, configured to cool the frequency converter (12)
Implementation Method 2
regulated by solenoid valves and temperature sensors to optimize cooling based on component needs
Implementation Method 3
regulated by solenoid valves and temperature sensors to optimize cooling based on component needs
Data Source
Figure 1
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Figure 3
AI summary
A cooling device for a frequency converter of a refrigerating or conditioning plant comprises at least one thermal exchange element (16) supplied with a total flow rate (QTOT) of refrigerating fluid; regulating means (23; 29) configured to selectively regulate the total flow rate (QTOT) of refrigerating fluid on the basis of at least one parameter indicative of the temperature of the frequency converter (12).