Refrigerant Compressor Control with Dual CPU Failover for Reliability
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Solution Overview
Problem
Refrigerant compressor systems face significant financial and operational risks due to failures, which can result in damage to chilled goods and disrupt large chilling systems, necessitating improved operational reliability.
Innovation Solution
The implementation of a dual central processing unit system within the control unit, where a second central processing unit takes over control functions in case of failure of the first, along with redundant input/output units and sensors, and parallel refrigerant compressors to ensure continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single central processing unit is used in the control system, then the device complexity is low, but the reliability is poor because a failure results in total system failure
Solution Approach 1:
The control system is segmented into multiple independent central processing units (first CPU and second CPU) that can operate autonomously. Each CPU can independently control the refrigerant compressor system, so that if one fails, the other can take over and maintain system operation, thereby improving reliability without requiring complete system redundancy
Solution Approach 2:
The second central processing unit is pre-configured with all necessary control functions and parameters before any failure occurs. It is ready to immediately take over control tasks when the first CPU fails, eliminating the need for reconfiguration or external intervention and ensuring continuous operation
2Reliability
If redundant components are added to prevent failures, then the reliability improves, but the device complexity and cost increase
Solution Approach 1:
The second central processing unit serves dual purposes: it acts as a standby unit for reliability purposes and simultaneously functions as an active control unit capable of independently managing the entire refrigerant compressor system. This multi-functionality reduces the need for separate dedicated backup components, thereby limiting the increase in system complexity
Data Source
AI summary
In order to improve the operational reliability of a refrigerant compressor system that includes a first refrigerant line that conducts expanded refrigerant, a second refrigerant line that conducts compressed refrigerant, at least one refrigerant compressor that is arranged between the first and the second refrigerant line and is driven by a motor, and a control unit for operating the refrigerant compressor system, it is proposed that the control unit should have a first central processing unit and at least one input/output unit for control variables that communicates with the first central processing unit, and that there should be associated with the first central processing unit a second central processing unit which, in the event of a failure of the first central processing unit, takes over the control functions for the purpose of controlling the refrigerant compressor system.