Racked Modular HVAC System for High Thermal Capacity and Flexibility

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Solution Overview

Problem

Modular design concepts have had limited success in HVAC, industrial process cooling, low-temperature heating, and refrigeration systems, lacking flexibility and high thermal capacity with a small footprint.

Innovation Solution

A novel modular design employing multi-module racking concepts with field-assembled components, allowing for high thermal capacity and flexibility, including air or water-cooled chillers, heater/chillers, and refrigeration units, with features like removable modules, ultra-low pressure drop piping, and integrated analytics for energy efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If modular design concepts are applied to HVAC and refrigeration systems, then flexibility and adaptability are improved, but thermal capacity and footprint efficiency deteriorate

Engineering Contradiction:

ImproveflexibilityVSAvoidthermal capacity

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The system is divided into multiple independent modular units, each capable of operating autonomously. These modules can be individually configured and combined to meet specific thermal capacity requirements while maintaining flexibility in system arrangement and scaling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple modular units are combined in parallel or series configurations to achieve high thermal capacity. The modules work together as an integrated system while retaining individual controllability, thus achieving both high capacity and flexibility simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If modular design concepts are applied to HVAC and refrigeration systems, then adaptability is improved, but system footprint and space efficiency worsen

Engineering Contradiction:

ImproveadaptabilityVSAvoidfootprint

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The modular units are designed to be stacked vertically or arranged in three-dimensional configurations, transitioning from two-dimensional horizontal placement to three-dimensional spatial utilization. This reduces the ground footprint while maintaining adaptability in system configuration.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Components and sub-assemblies are nested within each other in a hierarchical manner, with smaller modules contained within larger structural frameworks. This nesting approach maximizes space utilization and reduces the overall system footprint while preserving modular adaptability.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of repair

If individual modules are made removable for maintenance, then ease of repair is improved, but system complexity and assembly requirements worsen

Engineering Contradiction:

Improvemodule removabilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

Connection interfaces and mounting mechanisms are pre-configured and standardized during manufacturing, enabling quick attachment and detachment of modules without complex field assembly procedures. This preliminary preparation simplifies both installation and maintenance operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connection parameters and interface specifications are standardized across all modules, allowing for consistent and simplified assembly procedures. Standardized parameters reduce the complexity of module integration while maintaining ease of removal for maintenance purposes.

Inventive Principle:

Principle #35Parameter changes

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 solution enables efficient, flexible, and high-capacity HVAC and process cooling systems with minimal downtime, adaptable to various applications, and optimized energy use through programmable software and sensors, ensuring peak operational efficiency.

Implementation Method 1

a condenser configured to receive the refrigerant gas from the compressor and condense the refrigerant gas into a liquid

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 2

an expansion device configured to receive the liquid refrigerant from the condenser and reduce a pressure of the liquid refrigerant

Methodology Applied

Scientific EffectPressure reduction through expansion: Pressure Drop

Implementation Method 3

an evaporator configured to receive the refrigerant liquid from the expansion device and evaporate the refrigerant liquid into a gas

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11015854B2Modular system for heating and/or cooling requirements

Publication Date: 2021.05.25 JACOBI ROBERT W

AI summary

A racked modular system for heating and/or cooling requirements includes a first plurality of equipment modules, a second plurality of equipment modules, a first storage rack and a second storage rack. The first storage rack is constructed and arranged to receive the first plurality of equipment modules. The second storage rack is constructed and arranged to receive the second plurality of equipment modules. The disclosed system also includes a plurality of water manifolds which are constructed and arranged for interconnecting the first plurality of equipment modules with the second plurality of equipment modules. In one exemplary embodiment the equipment modules are chillers.