Multi-Evaporator Cooling System with Superheat-Based Flow Control
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Solution Overview
Problem
Conventional refrigeration systems with multiple evaporators face instability and inefficiency due to improper control of refrigerant flow, leading to increased power consumption and energy loss.
Innovation Solution
A controller-based cooling system that utilizes superheat of evaporators to stabilize refrigerant flow by controlling valves upstream and downstream of the evaporators, enabling fast switching between evaporators to maintain optimal superheat and temperature balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple evaporators operate independently at different temperature ranges and pressure, then the cooling system can serve multiple temperature zones, but the control complexity increases and power consumption rises
Solution Approach 1:
The patent combines multiple evaporators into a single integrated cooling system where they share common control mechanisms. The controller manages refrigerant distribution to multiple evaporators operating at different temperature ranges, reducing overall system complexity while maintaining the ability to serve multiple temperature zones simultaneously.
Solution Approach 2:
The system dynamically adjusts refrigerant flow distribution to evaporators based on real-time temperature and pressure conditions. The controller monitors system state and modifies valve positions and refrigerant allocation dynamically, allowing the system to adapt to varying cooling demands across different zones without requiring separate fixed control systems for each evaporator.
2Loss of energy
If the compressor turns on and off in cycles, then the system can reduce energy consumption during off-periods, but the temperature control stability deteriorates
Solution Approach 1:
The system performs preliminary cooling actions during compressor on-periods to pre-cool the refrigerant and thermal mass before the compressor shuts off. This preliminary action ensures that sufficient cooling capacity is stored in the system, allowing the compressor to remain off longer while maintaining temperature stability, thus reducing energy consumption without sacrificing control stability.
Solution Approach 2:
The controller continuously monitors temperature and pressure feedback from the system and uses this information to optimize compressor cycling patterns. By adjusting the timing and duration of compressor on/off cycles based on real-time system state, the feedback mechanism maintains temperature control stability while minimizing unnecessary energy consumption from frequent compressor startup and shutdown.
3Force
If a valve is opened before compressor start to equalize pressure, then the required start torque is reduced, but the control precision of refrigerant flow decreases
Solution Approach 1:
The valve is opened partially or for a limited duration before compressor start to equalize pressure difference without fully opening the refrigerant flow path. This partial action is sufficient to reduce the pressure differential and lower start torque requirements, while avoiding excessive valve opening that would compromise refrigerant flow control precision during normal operation.
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
Achieves improved cooling efficiency and energy savings by stabilizing the refrigerant flow, allowing simultaneous operation of multiple evaporators with precise temperature control.
Implementation Method 1
a controller configured to control the flow of refrigerant to and/or from at least one of said first evaporator and second evaporator based on the superheat of said at least one of the first evaporator and second evaporator
Data Source
AI summary
A cooling system includes a compressor (31), a condenser (32) and at least a first evaporator (34) and a second evaporator (35) connected in parallel with the first evaporator. A refrigerant is circulated in the cooling system. A controller (40) is provided and configured to control the flow of refrigerant to and/or from at least one of said first evaporator and second evaporator based on the superheat of said at least one of the first evaporator and second evaporator.