Multi-stage cooling system
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Solution Overview
Problem
Conventional cooling devices using nitrogen are energy-consuming, costly, and decreasing in compatibility with industry trends.
Innovation Solution
A multi-stage cooling system comprising a pressure-resistant container, a parallel-mode cooling device with first and second heat exchangers, and contactless test devices, which uses dry gas with a dew point temperature less than −10° C. and pressure greater than 1 atm to achieve efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional cooling devices use nitrogen for rapid cooling, then cooling speed is improved, but energy consumption increases and cost increases
Solution Approach 1:
The cooling process is divided into multiple stages with different heat exchangers (first heat exchanger for initial cooling, second heat exchanger for further cooling) operating at different power levels. This segmentation allows the system to achieve rapid cooling when needed while using lower power for maintenance cooling, resolving the contradiction between cooling speed and energy consumption.
Solution Approach 2:
The system dynamically switches between different heat exchangers based on real-time temperature requirements. The control unit activates the first heat exchanger for rapid cooling when temperature drops are needed, and switches to the second heat exchanger for lower-power maintenance cooling, making the cooling power adaptable rather than static.
2Speed
If conventional cooling devices use nitrogen for rapid cooling, then cooling speed is improved, but cost increases
Solution Approach 1:
The system changes the operational parameters by using a parallel configuration of heat exchangers with different power levels instead of relying on a single high-power nitrogen-based cooling system. This allows achieving cooling effects at lower costs by selecting appropriate heat exchangers based on actual needs rather than always using the most expensive rapid cooling method.
3Power
If a single high-power heat exchanger is used for cooling, then cooling capability is improved, but energy consumption increases
Solution Approach 1:
The cooling system is segmented into multiple heat exchangers (first and second heat exchangers) with different power levels operating in parallel. The first heat exchanger provides high-power cooling when rapid temperature reduction is needed, while the second heat exchanger provides lower-power cooling for maintenance. This segmentation resolves the contradiction by providing high cooling capability only when necessary while consuming less energy during normal operation.
Solution Approach 2:
Instead of using a single heat exchanger at full capacity continuously, the system applies partial action by selectively activating only the necessary heat exchanger based on current cooling requirements. The control unit determines whether to activate the first or second heat exchanger partially or fully, avoiding excessive energy consumption while maintaining adequate cooling capability.
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 system effectively reduces energy consumption by selectively using heat exchangers with different operation powers and quickly establishes a predetermined test environment for contactless test devices, enhancing overall test efficiency.
Implementation Method 1
The parallel-mode cooling device is configured to reduce a temperature of the dry gas in the gas storage room to the first cooling critical value through the first heat exchanger
Implementation Method 2
further to reduce the temperature of the dry gas from the first cooling critical value to a predetermined temperature through the second heat exchanger
Data Source
AI summary
A multi-stage cooling system includes a pressure-resistant container and a parallel-mode cooling device that is at least partially arranged in the pressure-resistant container. The pressure-resistant container can store a dry gas therein that has a dew point temperature being less than −10° C. and that has a pressure being greater than 1 atm. The parallel-mode cooling device includes two heat exchangers immersed in the dry gas. The two heat exchangers respectively have a first cooling critical value and a second cooling critical value that is less than the first cooling critical value. The parallel-mode cooling device is configured to reduce a temperature of the dry gas to the first cooling critical value through one of the two heat exchangers having a lower operation power, and then further to reduce the temperature of the dry gas through another one of the two heat exchangers having a higher operation power.