Heat Exchanger Refrigerant Tracking via Liquid-Level Weight Sensing
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Solution Overview
Problem
Existing refrigeration systems face challenges in accurately monitoring refrigerant levels and detecting leaks, particularly in heat exchangers, where mechanical floats are difficult to employ and infrared leak detectors have limitations.
Innovation Solution
A refrigeration system that includes sensors to generate signals indicative of liquid levels in heat exchangers and reservoirs, with a processor calculating the weight of refrigerant and comparing it to a known weight to determine any missing refrigerant, enabling continuous monitoring and leak detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical float is placed within a receiver vessel to monitor refrigerant level, then visual indication of refrigerant level is achieved, but the method is difficult to employ in heat exchangers such as condensers and only allows viewing during servicing operations
Solution Approach 1:
The patent replaces mechanical float systems with electronic sensors (capacitive, resistive, inductive, or optical sensors) that can continuously monitor refrigerant levels in heat exchangers and receiver vessels. These electronic sensors transmit signals to a processor that calculates refrigerant weight and monitors levels continuously, eliminating the need for mechanical components that are difficult to install in heat exchangers and require manual viewing during servicing.
2Reliability
If an infrared leak detector with air pump is used to sample air surrounding refrigeration system, then refrigerant leaks can be detected, but the system complexity increases and continuous monitoring of refrigerant quantity is limited
Solution Approach 1:
The patent extracts the leak detection function from complex infrared sampling systems and integrates it directly into the refrigeration system's existing sensor network. By using the same electronic sensors (capacitive, resistive, inductive, or optical) to monitor refrigerant quantity in heat exchangers and receiver vessels, the system can detect leaks through refrigerant quantity changes without requiring separate infrared detectors and air pumping mechanisms.
3Productivity
If sensors are installed in heat exchangers to monitor refrigerant level, then continuous monitoring is achieved, but the device complexity and difficulty of installation increase
Solution Approach 1:
The patent employs multi-functional electronic sensors that can operate in various refrigeration components (heat exchangers, receiver vessels, condensers) using the same sensor technology (capacitive, resistive, inductive, or optical). This universal approach allows continuous monitoring across the entire refrigeration system without requiring different sensor types for different locations, thereby reducing overall system complexity while maintaining continuous monitoring 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
This solution provides accurate and continuous monitoring of refrigerant levels and detects leaks effectively, ensuring stable operation and reducing refrigerant loss.
Implementation Method 1
a first sensor coupled to the heat exchanger and operable to generate a first signal indicative of a heat exchanger liquid level
Implementation Method 2
A processor is operable to calculate a first weight of liquid within the heat exchanger in response to the first signal, and to calculate a second weight of liquid within the reservoir in response to the second signal
Implementation Method 3
a condenser in fluid communication with the compressor to receive the flow of compressed refrigerant. The condenser is operable to cool the flow of compressed refrigerant
Data Source
AI summary
A refrigeration system includes a heat exchanger that is operable to cool a flow of compressed refrigerant and a first sensor coupled to the heat exchanger and operable to generate a first signal indicative of a heat exchanger liquid level. A reservoir is in fluid communication with the heat exchanger to receive the flow of cooled compressed refrigerant and a second sensor is coupled to the reservoir and is operable to generate a second signal indicative of a reservoir liquid level. A processor is operable to calculate a first weight of liquid within the heat exchanger in response to the first signal, and to calculate a second weight of liquid within the reservoir in response to the second signal.