Lubricant separator for a heating, ventilation, and air conditioning system
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Solution Overview
Problem
In HVAC systems, such as chiller units, lubricant loss occurs due to pressure differentials, leading to a higher rate of lubricant loss to the evaporator than return, causing inefficiency and potential system damage.
Innovation Solution
A lubricant separator device with a housing and vanes is integrated into the lubricant tank assembly, reducing the velocity of the heat transfer fluid mixture and allowing lubricant to coalesce and fall, thereby reducing carryover into the evaporator and minimizing lubricant loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a lubricant tank vent conduit is used to manage pressure differential in the compressor, then pressure control is improved, but lubricant loss to the evaporator increases
Solution Approach 1:
A lubricant separator is introduced as an intermediary component in the lubricant tank assembly. This separator intercepts the lubricant-heat transfer fluid mixture before it can be carried over to the evaporator, allowing lubricant to be separated and retained in the tank while permitting heat transfer fluid to pass through. This resolves the contradiction by adding a mediating element that prevents direct loss of lubricant through the vent conduit system.
Solution Approach 2:
The lubricant separator extracts lubricant from the lubricant-heat transfer fluid mixture. By removing the lubricant component from the flowing mixture, the system prevents lubricant carryover to the evaporator while maintaining pressure control functions. The extracted lubricant is retained in the tank, eliminating the harmful loss while preserving the necessary pressure management.
2Ease of operation
If lubricant is allowed to flow freely in the lubricant tank assembly, then lubricant circulation is improved, but lubricant carryover to the evaporator increases
Solution Approach 1:
The lubricant separator acts as an intermediary that selectively interacts with the lubricant-heat transfer fluid mixture. It allows lubricant to remain in the tank for circulation purposes while preventing it from being carried over to the evaporator. The separator mediates between the need for lubricant circulation and the need to prevent carryover loss.
Solution Approach 2:
The lubricant tank assembly is segmented into distinct functional zones by the lubricant separator. One zone allows lubricant circulation within the tank, while another zone prevents carryover to the evaporator. This segmentation enables both lubricant circulation and prevention of carryover to occur simultaneously in different spatial regions.
3Productivity
If the velocity of heat transfer fluid exiting the lubricant separator is high, then flow rate is improved, but lubricant carryover increases
Solution Approach 1:
The lubricant separator serves as an intermediary that reduces the velocity of the heat transfer fluid before it exits. By introducing this velocity-reducing element, the system maintains high flow rate capability while preventing lubricant carryover that would occur at high velocities. The mediator transforms the high-velocity flow into a lower-velocity flow that doesn't carry lubricant.
Solution Approach 2:
The lubricant separator changes the velocity parameter of the heat transfer fluid. It transforms the high-velocity inlet flow into a lower-velocity outlet flow, thereby maintaining productivity (flow rate) while eliminating the harmful effect of high velocity (lubricant carryover). This parameter transformation resolves the contradiction between flow rate and carryover prevention.
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 lubricant separator effectively reduces lubricant loss by allowing lubricant to settle and be reused, improving system efficiency and reducing the need for frequent lubricant replenishment.
Implementation Method 1
a plurality of vanes disposed on each side of the housing, the plurality of vanes having a portion that is disposed within the housing... on which a lubricant in the lubricant—heat transfer fluid mixture can coalesce
Implementation Method 2
the lubricant separator can reduce a velocity of a heat transfer fluid portion of the mixture exiting the lubricant separator
Implementation Method 3
allowing lubricant to coalesce and fall, thereby reducing carryover into the evaporator
Data Source
AI summary
A lubricant separator is disclosed. The lubricant separator can cause lubricant which is entrained with a heat transfer fluid (e.g., a lubricant—heat transfer fluid mixture) to coalesce and fall (e.g., via gravity) into a bottom portion of a lubricant tank assembly. The lubricant separator can also reduce a velocity of the lubricant—heat transfer fluid mixture as it enters the lubricant tank assembly. The velocity reduction can, for example, reduce an amount of splashing of the lubricant that occurs as the lubricant—heat transfer fluid mixture enters the lubricant tank assembly. The velocity reduction can also, for example, be relatively more conducive to lubricant droplets falling into the bottom portion of the lubricant tank assembly as the flow of the heat transfer fluid is provided to a heat transfer fluid return conduit of the lubricant tank assembly.