On-Demand Air Bleeding Using Level Sensors to Reduce Refrigerant Loss
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Solution Overview
Problem
Conventional air bleeding systems in refrigeration systems are inefficient due to fixed-time controls, leading to suboptimal operation, energy waste, and potential refrigerant loss, with existing heat exchangers being suboptimal in efficiency and durability.
Innovation Solution
An on-demand air bleeding method and system using level sensors to control valve openings, combined with a stainless-steel parallel plate heat exchanger, ensuring efficient withdrawal of non-condensable gases while minimizing refrigerant loss, and featuring intelligent control for dynamic system adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fixed-time control is used for air bleeding, then the system operation is simplified, but the bleeding efficiency decreases and refrigerant loss increases
Solution Approach 1:
The patent implements feedback control by using level sensors to detect the actual refrigerant level in the receiver and adjusting the air bleeding valve operation accordingly. The controller receives level sensor signals and automatically opens or closes the bleeding valve to maintain optimal refrigerant levels, replacing fixed-time control with dynamic feedback-based control that responds to actual system conditions.
Solution Approach 2:
The system performs self-service by automatically monitoring its own refrigerant levels through level sensors and autonomously controlling the air bleeding process without external intervention. The controller continuously adjusts the bleeding valve based on real-time level data, enabling the system to self-regulate and optimize its own operation.
2Device complexity
If fixed-time control is used for air bleeding, then the control system is simpler, but energy consumption increases
Solution Approach 1:
The feedback control system uses level sensors to continuously monitor refrigerant levels and adjusts the air bleeding valve operation in real-time. This prevents unnecessary bleeding operations and refrigerant loss, optimizing energy consumption by only performing bleeding when actually needed based on measured conditions rather than fixed schedules.
Solution Approach 2:
The system dynamically changes the bleeding operation parameters (timing, duration, frequency) based on detected refrigerant levels. Instead of fixed-time control, the bleeding parameters are adjusted according to actual system state, reducing unnecessary energy expenditure while maintaining effective air removal.
3Ease of manufacture
If conventional heat exchangers are used, then the system cost is lower, but thermal efficiency and durability decrease
Solution Approach 1:
The patent employs heat exchangers constructed with composite materials, specifically stainless steel plates, which provide superior thermal efficiency and durability compared to conventional materials. The use of stainless steel composite structure in the plate heat exchanger enhances both thermal performance and resistance to corrosion, improving overall system reliability and longevity.
Solution Approach 2:
The plate heat exchanger utilizes thin plate structures that increase surface area for heat transfer while maintaining compact size. The thin film design of the plates improves thermal efficiency by reducing thermal resistance, while the stainless steel material provides durability and resistance to degradation over time.
4Device complexity
If timer-based solenoid control is used, then the valve operation is simpler, but refrigerant loss increases
Solution Approach 1:
The valve control system uses feedback from level sensors to determine when bleeding is actually needed. The controller receives real-time level information and only opens the bleeding valve when refrigerant level indicates air presence, preventing unnecessary valve operations that would cause refrigerant loss while maintaining simple valve mechanics.
Solution Approach 2:
The patent replaces pure mechanical timer-based control with an intelligent control system that uses electrical sensors and electronic controllers to determine valve operation timing. This substitution allows the system to make intelligent decisions based on actual conditions, reducing refrigerant loss while keeping the physical valve structure relatively simple.
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 achieves higher efficiency, faster startup, reduced energy consumption, and extended exchanger life by adaptively managing bleed points, ensuring optimal operation and minimizing refrigerant loss.
Implementation Method 1
conduct the condensed fluid through a heat exchanger, in order to cool it
Implementation Method 2
condensation of the mixture in the heat exchanger, until the refrigerant fluid remains in a fluid state
Implementation Method 3
conduction of non-condensable gases withdrawn from the high-pressure tank to a bubbler by pressure difference
Implementation Method 4
conduction of bubbles and droplets of condensed refrigerant fluid from the tank to the refrigeration system by gravity
Data Source
AI summary
An on-demand air bleeding method is provided in which the refrigeration plant valve is opened until all of the non-condensable gases have been withdrawn from the bleed point, the system switches to receiving refrigerant fluid in the fluid state, which is conveyed to the high-pressure tank; and when the increase in the level of the tank is detected, the first refrigeration plant valve is closed and a second refrigeration plant valve is opened and begins collecting air from a new point in the system, and when the pressure in the tank reaches a threshold value, an air valve is actuated and the non-condensable gases are expelled from the tank to a bubbler; and when the level of fluid reaches a threshold, a feedback valve is actuated and the fluid is returned to the system until the fluid level in the tank returns to an initial value.