Automatic refrigerant filling
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Solution Overview
Problem
The existing methods for filling refrigeration circuits with refrigerant are inefficient and prone to incorrect filling, leading to potential leaks and the need for complex and costly removal of excess refrigerant, which can cause system damage.
Innovation Solution
A valve control system that uses a control unit to calculate parameters from temperature and pressure sensor data to adjust the valve, ensuring the system reaches target superheat or subcooling values, potentially eliminating the need for additional sensors and allowing for real-time monitoring and automatic correction, with wireless data transmission and integration of flow sensor and scale data for precise refrigerant management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual filling methods are used, then the filling process is simple to implement, but the accuracy of refrigerant filling is poor leading to incorrect filling
Solution Approach 1:
The control unit continuously receives measurement data from temperature and pressure sensors during the filling process, calculates the current parameter (superheat or subcooling), and compares it with the target value. Based on this feedback loop, the control unit automatically adjusts the valve opening degree to achieve precise filling accuracy of within ±5% of the target value.
Solution Approach 2:
The patent replaces manual mechanical filling operations with an automated electronic control system. The control unit processes sensor data, performs thermodynamic calculations, and electronically controls the valve actuator, substituting the need for manual intervention and simple mechanical filling mechanisms with an intelligent automated system.
2Reliability
If no real-time monitoring is implemented, then the system is simpler, but the risk of incorrect filling and system damage increases
Solution Approach 1:
Temperature and pressure sensors provide real-time monitoring data to the control unit throughout the filling process. The system continuously calculates the current superheat or subcooling parameter and compares it with target values, enabling real-time detection of deviations and automatic correction to prevent incorrect filling and system damage.
Solution Approach 2:
The control unit is pre-programmed with target parameter values for superheat or subcooling based on the specific refrigeration system requirements. Before filling begins, the system establishes these reference values, allowing it to immediately compare actual measurements against targets and take preventive action if deviations occur.
3Measurement precision
If multiple sensors are used for monitoring, then the measurement accuracy improves, but the device complexity and cost increase
Solution Approach 1:
The temperature and pressure sensors serve multiple functions: they monitor the thermodynamic state during filling, provide data for calculating superheat or subcooling parameters, enable real-time safety monitoring, and support post-filling system diagnostics. This multi-functionality reduces the need for additional dedicated sensors while maintaining high measurement precision.
Solution Approach 2:
The system derives multiple measurement parameters (temperature, pressure, superheat, subcooling) from a combination of two sensors rather than requiring separate dedicated sensors for each parameter. By using thermodynamic relationships and the ideal gas law, the system calculates derived parameters from basic sensor measurements, reducing sensor quantity while maintaining comprehensive monitoring capability.
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
This solution simplifies the refrigerant filling process, reduces the risk of incorrect filling, and minimizes the risk of leaks and system damage by ensuring accurate refrigerant levels, enhancing operational efficiency and safety.
Implementation Method 1
a temperature sensor (3) which is set up to determine a temperature in the refrigeration circuit
Implementation Method 2
a pressure sensor (4) which is set up to determine a pressure in the refrigeration circuit
Implementation Method 3
the control unit (5) is set up to calculate a parameter from the measurement data of the temperature sensor (3) and/or the pressure sensor (4)
Data Source
Figure 1~2
AI summary
It is therefore proposed to provide a valve control (1) for filling a refrigeration circuit with refrigerant, comprising a valve (2), a temperature sensor (3), a pressure sensor (4) and a control unit (5), wherein the control unit (5) calculates a parameter from the measurement data of the temperature sensor (3) and/or the pressure sensor (4), and wherein the control unit (5) actuates the valve (2) until the calculated parameter reaches a target value (Fig. 1).