Multiple Compressor Oil Balancing System with Adaptive Valve Control
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Solution Overview
Problem
Compressors in tandem configurations face challenges in balancing oil levels, leading to potential oil starvation and adverse effects if not properly managed, as historical methods like calibrated orifices are insufficient for steady performance.
Innovation Solution
An oil balancing system with an oil equalization line, valves, and a module that monitors oil levels and applies corrective actions, including control signals to solenoid valves, to diagnose and mitigate oil imbalances, and includes self-learning and leak detection capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a calibrated orifice in the suction manifold is used to balance oil levels, then a desired pressure differential is achieved, but the system lacks adaptability to changing operating conditions leading to oil imbalance
Solution Approach 1:
The patent replaces the static calibrated orifice with a dynamic solenoid valve that can adjust its opening degree based on real-time oil level sensor feedback. This allows the system to adapt oil flow rates to changing operating conditions while maintaining reliable oil level balance between compressors.
Solution Approach 2:
The patent implements a feedback control system where oil level sensors continuously monitor oil levels in each compressor and send signals to the controller, which then adjusts the solenoid valve opening degree accordingly. This closed-loop feedback mechanism ensures adaptability to varying operating conditions while maintaining oil balance.
2Productivity
If manual monitoring and adjustment of oil levels is performed, then system complexity is reduced, but productivity and response time deteriorate
Solution Approach 1:
The patent implements a self-service automated system where oil level sensors and controllers continuously monitor and adjust oil levels without manual intervention. The system automatically detects imbalances and activates solenoid valves to correct them, significantly improving response time while the added automation components increase system complexity.
Solution Approach 2:
The patent replaces manual mechanical monitoring and adjustment with an automated electronic control system featuring sensors, controllers, and electronically actuated solenoid valves. This substitution of manual operations with automated electronic systems improves productivity and response time at the cost of increased device complexity.
3Manufacturing precision
If a solenoid valve with continuous adjustment is used, then oil balancing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a dynamic solenoid valve that can continuously adjust its opening degree under electronic control, enabling precise oil flow regulation. This dynamic adjustment capability achieves high oil balancing precision while the electronic control system manages the complexity of valve actuation.
Solution Approach 2:
The patent changes the control parameter of the solenoid valve from fixed positions to continuously variable opening degrees, allowing precise adjustment of oil flow rates. This parameter change enables high precision oil balancing, while the electronic control system manages the complexity introduced by continuous adjustment capability.
Data Source
AI summary
An oil balancing system for a multiple compressor system is provided. The oil balancing system includes an oil equalization line disposed between a first compressor and a second compressor. A first solenoid valve is provided in the oil equalization line. A first signal corresponds to a first oil level in the first compressor. A second signal corresponds to a second oil level in the second compressor. An oil balancing module uses the first signal and the second signal to diagnose an oil imbalance between the first compressor and the second compressor, and applies corrective action, whereby the corrective action includes sending control signals to operate at least one of the first compressor, the second compressor, or the first solenoid valve in a way that eliminates the oil imbalance.