Hydraulic Balancing Control for Variable-Load Heating Strands
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Solution Overview
Problem
Existing heating and cooling systems face challenges in maintaining precise hydraulic conditions and adapting to changing energy consumption demands, particularly in older systems where optimal static adjustment is not possible, leading to inefficiencies and energy wastage due to undersupply or oversupply of pipeline strands.
Innovation Solution
The method involves using differential pressure sensors and actuators in pipeline sections to continuously measure and regulate differential pressures, with a computing unit generating control commands to maintain optimal flow and pressure, prioritizing the hydraulically most unfavorable section and adjusting pump capacity to minimize energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If static regulation of volume flows using line regulating valves is used, then the system is simple to operate, but the hydraulic conditions are not precise enough under frequently changing load conditions
Solution Approach 1:
The patent implements dynamic hydraulic balancing by continuously measuring differential pressures and automatically adjusting control valve positions based on real-time load conditions. The system transitions from static pre-adjustment to dynamic adaptation, where the hydraulic balance is constantly optimized according to actual operating conditions, resolving the contradiction between precision and complexity.
Solution Approach 2:
The system incorporates differential pressure sensors that continuously monitor the hydraulic conditions and feed this information back to the control unit. The control unit processes the feedback signals and automatically adjusts the control valves to maintain optimal hydraulic balance, achieving high precision through closed-loop control without requiring complex manual adjustment procedures.
2Manufacturing precision
If optimal static adjustment is attempted in older systems with unknown pipe routing, then manufacturing precision might be improved, but the ease of manufacture and installation deteriorates
Solution Approach 1:
The system performs self-balancing by automatically measuring differential pressures across various pipeline sections and adjusting control valves based on real-time measurements. This eliminates the need for manual hydraulic balancing during installation, allowing older systems with unknown routing to achieve optimal hydraulic conditions automatically without requiring expert intervention or detailed knowledge of the pipe network.
Solution Approach 2:
The patent replaces manual mechanical adjustment procedures with an automated electronic control system. Differential pressure sensors and electronic control valves substitute for traditional manual balancing valves and expert adjustment procedures, enabling precise hydraulic balancing in complex older systems without requiring manual intervention or detailed knowledge of the original pipe routing.
3Adaptability or versatility
If line flow variables are continuously measured and controlled to stored values, then the adaptability to changing load conditions is improved, but the device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it stores reference differential pressure values from the design phase, continuously reads current differential pressure measurements from sensors, compares measured values with reference values, and automatically generates control commands for the actuators. This multi-functional integration achieves high adaptability without proportionally increasing system complexity.
Solution Approach 2:
The system establishes a closed-loop feedback control mechanism where differential pressure sensors continuously monitor the actual hydraulic conditions, the control unit compares these measurements with reference values stored from the design phase, and automatically adjusts control valves to maintain optimal flow distribution. This feedback-driven approach enables continuous adaptation to changing load conditions using a relatively simple control architecture.
4Reliability
If the circulating pump capacity is increased to ensure sufficient supply to all consumers, then the reliability of supply is improved, but the energy consumption increases
Solution Approach 1:
The patent implements dynamic hydraulic balancing that automatically adjusts the differential pressure distribution across the network according to actual load conditions. By continuously optimizing the hydraulic balance, the system ensures reliable supply to all consumers while minimizing the required pump capacity, as the available pressure is distributed more efficiently rather than being wasted in well-supplied sections.
Solution Approach 2:
The system dynamically changes the differential pressure parameters across different pipeline sections based on actual flow demands. By adjusting the control valves, the system optimizes the pressure distribution to match the current load pattern, ensuring sufficient supply pressure where needed while reducing pressure losses and pump energy consumption in sections with lower demand.
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 approach ensures dynamic hydraulic balancing, reducing energy consumption and flow noise, while maintaining optimal supply under changing load conditions, and minimizing pressure losses by regulating the circulating pump speed.
Implementation Method 1
one differential pressure sensor per pipeline section records the differential pressures from the inlet and outlet sides of the control fittings
Implementation Method 2
at least one circulating pump...the differential pressure required in the individual pipeline sections and in the entire system is determined
Data Source
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AI summary
The invention relates to a method for automatic hydraulic compensation of heating and/or cooling systems (1) having a heat and/or cold producer (2), a plurality of loads (4) connected in strands, and a circulating pump (5), wherein control valves (8) provided with actuating drives (7) are installed in the pipeline strands (6) in order to control the strand differential pressures, wherein in a first method step the differential pressures of the inlet side (10) and outlet side (11) of the control valves (8) are detected and subsequently the strand differential pressures between the feed line (12) and the return line (13) are detected by one differential pressure sensor (9) per pipeline strand (6) and the detected measured data are read into a computing unit (14) and are stored in said computing unit, and in a second method step the strand differential pressures in all pipeline strands (6) are continuously measured, the measured data are transferred to the computing unit (14) and compared with the stored data pattern, wherein actuating commands are generated from the determined comparison data by the computing unit (14). The current strand differential pressures are controlled to the stored target differential pressures by the actuating drives (7) of the control valves (8) by means of said actuating commands.