Multi-Evaporator Refrigerant Charge Monitoring for Leak Isolation
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Solution Overview
Problem
Refrigeration systems face challenges in managing refrigerants with low global warming potential, as they may become more flammable, leading to increased regulatory pressure and the need for effective leak detection and mitigation systems.
Innovation Solution
A refrigerant monitoring system that includes modules to determine the amount of refrigerant in condensers, evaporators, and lines, and takes remedial actions such as isolating valves and operating the compressor to manage leaks, ensuring the refrigerant charge remains below a predetermined level to prevent leaks and maintain safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If low global warming potential refrigerants are used, then environmental impact is reduced, but flammability increases
Solution Approach 1:
The system divides the refrigeration system into multiple zones (evaporators, condensers, refrigerant lines) and monitors refrigerant charge in each zone separately. This segmentation allows for localized leak detection and isolation, enabling the use of flammable refrigerants by containing potential hazards to specific segments rather than the entire system.
Solution Approach 2:
The patent introduces an intermediary monitoring and control system that acts as a mediator between the refrigerant and safety requirements. This system continuously monitors refrigerant charge levels and provides feedback control, allowing the system to operate safely with flammable refrigerants by maintaining charge levels below hazardous thresholds.
2Reliability
If refrigerant leak detection and mitigation systems are implemented, then safety is improved, but system complexity increases
Solution Approach 1:
The monitoring system performs multiple functions using a single integrated platform: it calculates refrigerant charge levels, detects leaks, determines system zones, and controls mitigation actions. This multi-functionality reduces the need for separate dedicated systems for each safety function, thereby limiting the increase in overall system complexity while maintaining high safety standards.
Solution Approach 2:
The system automatically monitors refrigerant charge levels and detects leaks without requiring manual intervention. When leaks are detected, the system autonomously executes mitigation actions such as isolating affected zones or adjusting refrigerant distribution, reducing the need for complex external control mechanisms and human oversight.
3Loss of information
If total refrigerant charge is monitored, then leak detection capability is improved, but measurement precision requirements increase
Solution Approach 1:
Instead of requiring high-precision measurement of total refrigerant charge in the entire system, the patent segments the system into multiple zones and monitors refrigerant charge in each zone separately. This approach allows for effective leak detection by comparing expected versus actual charge in specific segments, reducing the overall measurement precision requirements while maintaining or improving leak detection capability.
Solution Approach 2:
The system continuously monitors refrigerant charge levels in different zones and uses feedback from these measurements to detect leaks. By comparing expected refrigerant distribution patterns with actual measurements over time, the system can detect leaks even with moderate measurement precision, as the feedback mechanism amplifies the signal of charge loss.
Data Source
AI summary
A condenser charge module is configured to: determine a first amount of refrigerant in each condenser of one or more condensers of a refrigeration system; determine a total condenser amount of refrigerant based on the one or more first amounts. An evaporator charge module is configured to: determine a second amount of refrigerant in each evaporator of two or more evaporators of the refrigeration system; and determine a total evaporator amount of refrigerant based on the two or more second amounts. A line charge module is configured to: determine a third amount of refrigerant in each refrigerant line of multiple refrigerant lines of the refrigeration system; and determine a total line amount of refrigerant based on the multiple third amounts. A total module is configured to determine a total amount of refrigerant in the refrigeration system based on the total condenser, the total evaporator, and the total line amounts.