Heat Source Unit Cooling Layout for Electric Box Heat Recovery
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Solution Overview
Problem
Existing heat source units for air conditioners dissipate significant heat, leading to increased temperatures in installation environments and potential need for additional cooling, especially when installed in confined spaces, and pose risks to fragile refrigerant piping during maintenance.
Innovation Solution
Incorporating a cooling heat exchanger connected to the refrigerant circuit that recovers heat from electrical components and uses it within the refrigerant system, minimizing heat dissipation by arranging it downstream of electrical components and utilizing a bypass line with a valve for controlled operation, thereby reducing heat expulsion and maintaining system efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a cooling heat exchanger is added to cool the air passage and reduce heat dissipation, then heat dissipation is reduced, but device complexity increases
Solution Approach 1:
The cooling heat exchanger is merged with the existing refrigerant circuit system. The heat exchanger utilizes the refrigerant that is already circulating through the air conditioner, integrating the cooling function into the existing thermal management infrastructure rather than adding a completely separate cooling system.
Solution Approach 2:
The cooling heat exchanger serves multiple functions: it cools the air passage, recovers heat from the refrigerant, and prevents overheating of electrical components. This multi-functionality reduces the need for separate cooling systems and minimizes overall device complexity while achieving heat dissipation reduction.
2Loss of energy
If the cooling heat exchanger is arranged downstream of electrical components, then heat dissipation is reduced, but maintenance difficulty increases due to refrigerant piping accessibility
Solution Approach 1:
The heat exchanger is divided into distinct sections: a first portion that contacts the electrical component for heat absorption, and a second portion that extends outside the electric box for refrigerant piping connection. This segmentation allows the heat exchanger to fulfill its cooling function while maintaining accessibility of the refrigerant connections for maintenance.
Solution Approach 2:
The heat exchanger acts as an intermediary element between the electrical components and the refrigerant circuit. It is positioned to thermally couple with the electrical component while maintaining a physical connection point outside the electric box, serving as a bridge that enables both heat transfer and maintenance accessibility.
3Loss of energy
If the cooling heat exchanger recovers heat from electrical components, then heat dissipation is reduced, but the air temperature for cooling electrical components may become too low causing condensation
Solution Approach 1:
The system incorporates temperature sensing and control mechanisms that monitor the air temperature in the air passage and adjust the refrigerant flow through the cooling heat exchanger accordingly. This feedback control prevents the air temperature from dropping below the dew point, thereby avoiding condensation while still achieving heat dissipation reduction.
Solution Approach 2:
The system dynamically adjusts the refrigerant flow rate and temperature parameters through the cooling heat exchanger based on operating conditions. By changing these parameters in real-time, the system maintains optimal air temperature for cooling electrical components without causing condensation, balancing heat recovery with prevention of harmful moisture accumulation.
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 effectively reduces heat dissipation from the heat source unit, minimizing the need for additional cooling in installation environments and preventing damage to refrigerant piping during maintenance, while maintaining the air conditioner's operational capacity and efficiency.
Implementation Method 1
a cooling heat exchanger (22) to be connected to the refrigerant circuit of the air conditioner and flown through by a refrigerant. The cooling heat exchanger is arranged so as to be flown through by the air flow induced through the air passage of the electric box, whereby the air is cooled.
Data Source
AI summary
A heat source unit for an air conditioner that includes a refrigerant circuit includes: an external housing; a cooling heat exchanger disposed in the external housing and that is connected to the refrigerant circuit; a controller that controls the valve; and a first temperature sensor disposed within the external housing. The external housing accommodates: a compressor connected to the refrigerant circuit; a heat source heat exchanger that is connected to the refrigerant circuit and that exchanges heat between a refrigerant circulating in the refrigerant circuit and a heat source; and an electric box. The electric box includes a top and a plurality of side walls; accommodates electrical components that control the air conditioner; and further includes an air passage that comprises an air inlet and an air outlet.