Modular Chiller Control for Capacity Scaling and Repair Continuity

Solution Overview

Problem

Chiller units have long manufacturing lead times and are prone to extended downtime during repairs, leading to dissatisfaction with production timelines and air conditioning disruptions in large buildings.

Innovation Solution

A modular chiller system comprising multiple modules with a main control device and module control devices that allow for simultaneous or successive operation of chiller modules, enabling flexible power application and efficient refrigeration capacity adjustment based on load requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a chiller unit increases in capacity, then the refrigeration ability increases, but the manufacturing lead time increases

Engineering Contradiction:

Improverefrigeration abilityVSAvoidmanufacturing lead time

Core Design Contradiction:

PowerVSLoss of time

Solution Approach 1:

The chiller unit is divided into multiple independent chiller modules (first chiller module, second chiller module, etc.), each capable of operating independently. This segmentation allows the system to achieve high refrigeration capacity through parallel operation of multiple smaller modules rather than manufacturing a single large-capacity unit, thereby reducing manufacturing lead time while maintaining high power output.

Inventive Principle:

Principle #1Segmentation

2Power

If a chiller unit increases in capacity, then the refrigeration ability increases, but the volume increases

Engineering Contradiction:

Improverefrigeration abilityVSAvoidchiller unit volume

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

The chiller unit is divided into multiple independent chiller modules (first chiller module, second chiller module, etc.), each capable of operating independently. This segmentation allows the system to achieve high refrigeration capacity through parallel operation of multiple smaller modules rather than manufacturing a single large-capacity unit, thereby reducing manufacturing lead time while maintaining high power output.

Inventive Principle:

Principle #1Segmentation

3Reliability

If a chiller unit is repaired, then the malfunction is fixed, but the operation time is restricted

Engineering Contradiction:

Improveoperation continuityVSAvoidrepair downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The chiller unit is divided into multiple independent chiller modules (first chiller module, second chiller module, etc.), each capable of operating independently. When one module malfunctions, others can continue operating, significantly reducing repair downtime and maintaining operation continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control system dynamically adjusts the operation parameters of individual modules based on their status. When a module malfunctions, the control device changes the operational parameters by activating other modules to compensate, thereby maintaining overall system reliability and minimizing operation time restriction during repairs.

Inventive Principle:

Principle #35Parameter changes

4Power

If multiple chiller modules are operated simultaneously, then the refrigeration capacity increases, but the power consumption increases

Engineering Contradiction:

Improverefrigeration capacityVSAvoidpower consumption

Core Design Contradiction:

PowerVSUse of energy by moving object

Solution Approach 1:

The control system dynamically adjusts the operation of individual modules based on real-time load requirements. The control device can selectively activate or deactivate modules, and adjust their operating parameters, to match the actual refrigeration demand, thereby optimizing power consumption while maintaining adequate refrigeration capacity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system dynamically adjusts the operation parameters of individual modules based on their status. When a module malfunctions, the control device changes the operational parameters by activating other modules to compensate, thereby maintaining overall system reliability and minimizing operation time restriction during repairs.

Inventive Principle:

Principle #35Parameter changes

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 modular design enhances productivity and market responsiveness by reducing manufacturing lead times, minimizing downtime during repairs, and optimizing power consumption while maintaining reliable air conditioning operations.

Implementation Method 1

a refrigerant circulating in a refrigeration system and cold water circulating between warm areas and the refrigeration system are heat-exchanged with each other to cool the cold water

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS9587867B2Chiller system and control method thereof

Publication Date: 2017.03.07 LG ELECTRONICS INC

AI summary

A chiller system and a control method thereof includes a plurality of chiller modules in which a refrigeration cycle is performed to supply cold water, a main control device generating an operation signal to simultaneously or successively operate the plurality of chiller modules, a module control device provided in each of the plurality of chiller modules to control an operation of each of the plurality of chiller modules on the basis of the operation signal of the main control device, and a starting device communicably connected to the module control device to selectively apply power into the plurality of chiller modules.