Refrigerant Compressor Multi-Mode Control for Partial Load Efficiency
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Solution Overview
Problem
Refrigerant compressors face challenges in optimizing their operation for partial performance conditions, particularly in achieving efficient and energy-saving modes.
Innovation Solution
The refrigerant compressor is designed to operate in multiple modes, with adjustable speed control using a frequency converter and an operating condition controller, allowing activation or deactivation of cylinder banks to match varying performance requests, optimizing efficiency and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the refrigerant compressor operates in a single fixed mode, then the structure is simple, but the efficiency is low under partial performance conditions
Solution Approach 1:
The patent implements multiple operating modes (first operating mode with all cylinder banks activated, second operating mode with some cylinder banks deactivated) that can be dynamically selected based on performance requirements. This dynamic configuration allows the compressor to adapt its structure and operation to match varying load conditions, thereby maintaining high efficiency across different performance levels while avoiding the need for a completely complex multi-speed mechanism.
2Device complexity
If the compressor speed is fixed, then the control system is simple, but the energy consumption is high under partial load conditions
Solution Approach 1:
The patent employs a frequency converter to enable continuous variable speed control of the electric motor, allowing the compressor to operate at optimized speeds for different load conditions. Combined with the operating condition controller that selects between multiple operating modes, this dynamic speed adjustment significantly reduces electrical power consumption during partial performance conditions while maintaining a relatively simple control architecture.
Solution Approach 2:
The patent changes the operational parameters by introducing multiple operating modes with different cylinder bank configurations and speed ranges. The operating condition controller selects the appropriate mode and speed based on the performance request signal, thereby optimizing the balance between electrical power consumption and refrigeration output for each specific operating condition.
3Productivity
If all cylinder banks are always activated, then the maximum performance is maintained, but the energy consumption increases during partial load conditions
Solution Approach 1:
The patent divides the cylinder banks into separatable groups that can be independently activated or deactivated. The mechanical performance control unit enables selective deactivation of specific cylinder banks based on the required refrigeration output. This segmentation allows the system to match the active compression capacity to the actual load, reducing energy consumption during partial performance conditions while maintaining the capability for maximum performance when all cylinder banks are activated.
Solution Approach 2:
The system dynamically adjusts the number of active cylinder banks based on the operating mode selected by the operating condition controller. During partial performance conditions, some cylinder banks are deactivated to reduce energy consumption, while during maximum performance conditions, all cylinder banks are activated. This dynamic configuration optimizes the balance between refrigeration output and electrical power consumption.
Data Source
AI summary
Refrigerant compressor for refrigeration systems, comprising an electric motor, at least two cylinder banks and a mechanical performance control unit for activating and deactivating at least one of the cylinder banks in order to activate or deactivate its refrigerant output, wherein, for the purpose of operation in partial performance conditions, the refrigerant compressor is operable in at least two different operating modes, of which each provides an activation or deactivation of the cylinder banks that is different from the other operating modes, wherein associated with the refrigerant compressor is a frequency converter for controlling the speed of the electric motor, wherein associated with the refrigerant compressor is an operating condition controller that, in accordance with a performance request signal supplied to it for operation of the refrigerant compressor in the partial performance condition corresponding to this performance request signal, operates the refrigerant compressor in an operating mode that is selected from at least two different operating modes and at a speed adapted to the selected operating mode, for the purpose of achieving this partial performance condition.