Automatic refrigerant filling
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Solution Overview
Problem
Existing refrigerating circuit filling processes are inefficient and prone to improper refrigerant filling, leading to laborious corrections and potential damage due to leaks or overfilling, as they rely on manual measurements and lack precise control mechanisms.
Innovation Solution
A valve controller that calculates parameters from temperature and pressure sensor data to automatically adjust the valve position, eliminating the need for additional flow rate sensors and enabling real-time monitoring and control, with wireless connectivity and optional flow sensors or balances for precise refrigerant measurement and leak detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual measurements and control are used for refrigerant filling, then the process is simple in terms of equipment, but the filling precision and reliability are poor leading to improper filling
Solution Approach 1:
The controller continuously receives measurement data from temperature and pressure sensors, calculates the current state parameter, compares it with the target value, and adjusts the valve actuator accordingly to maintain the refrigerant filling at the desired state. This closed-loop feedback mechanism ensures precise filling while automating the control process.
Solution Approach 2:
The patent replaces manual mechanical measurement and control operations with an automated electronic control system that uses sensors, a controller, and an actuator to precisely control refrigerant filling based on calculated state parameters and target values.
2Device complexity
If no additional flow rate sensors are used, then the device complexity is reduced, but the measurement precision of refrigerant flow may be insufficient
Solution Approach 1:
The controller acts as an intermediary that calculates the refrigerant filling state by processing temperature and pressure sensor data through thermodynamic relationships, thereby inferring flow information without requiring direct flow rate sensors. This indirect measurement approach reduces device complexity while maintaining measurement capability.
Solution Approach 2:
The patent transforms the measurement approach by changing from direct flow rate measurement to indirect state parameter calculation. By measuring temperature and pressure and calculating the resulting state parameter, the system achieves flow information without direct flow sensors, reducing complexity while preserving precision.
3Productivity
If automated control is implemented, then the productivity of filling operation is improved, but the device complexity increases due to additional control components
Solution Approach 1:
The controller performs multiple functions: receiving sensor data, calculating current state parameters, comparing with target values, and controlling the valve actuator. This multi-functional approach consolidates control operations into a single device, improving productivity while limiting the increase in overall system complexity.
Solution Approach 2:
The automated control system enables the filling operation to self-regulate by continuously monitoring state parameters and automatically adjusting the valve position to maintain target conditions, eliminating the need for manual intervention and significantly improving filling operation efficiency.
4Reliability
If real-time monitoring is implemented, then the reliability of filling process is improved, but the device complexity increases due to continuous measurement and control
Solution Approach 1:
The continuous feedback loop between sensors, controller, and actuator enables real-time monitoring and automatic correction of deviations from target filling state, significantly improving the reliability of the filling process by preventing improper filling before it occurs.
Solution Approach 2:
The system performs preliminary calculation of the current state parameter and comparison with target value before completing the filling operation, allowing proactive adjustment to prevent improper filling and ensuring reliable results throughout the process.
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 reduces the risk of improper filling, ensures accurate refrigerant quantity, and minimizes labor and equipment requirements by automating the filling process, providing real-time monitoring and preventing damage from overfilling or leaks.
Implementation Method 1
a temperature sensor
Implementation Method 2
a pressure sensor
Implementation Method 3
the controller calculates a parameter from the measurement data of the temperature sensor and/or the pressure sensor
Data Source
AI summary
A valve controller (1) for filling a refrigerating circuit with refrigerant includes a valve (2), a temperature sensor (3), a pressure sensor (4) and a controller (5). The controller (5) is configured to calculate a parameter from the measurement data of the temperature sensor (3) and/or the pressure sensor (4), and the controller (5) is further configured to activate the valve (2) until the calculated parameter has reached a target value.