Cooling system
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Solution Overview
Problem
Existing cooling systems often require shutdown and evacuation of spaces to diagnose and repair refrigerant leaks, leading to significant losses and safety concerns due to the inability to isolate and manage leaks effectively.
Innovation Solution
A cooling system equipped with sensors to detect refrigerant concentrations and a controller that closes the expansion valve to isolate leaks when concentrations exceed a first threshold, and activates an exhaust system to evacuate refrigerant when concentrations reach a second threshold, allowing for leak isolation and repair without shutting down the entire system or evacuating the space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire cooling system is shut down to diagnose and repair refrigerant leaks, then safety is ensured and leak repair is possible, but operational disruptions occur and productivity is lost
Solution Approach 1:
The cooling system is divided into multiple independent zones, each with its own expansion valve. When a refrigerant leak is detected in one zone, only the expansion valve for that specific zone is closed, isolating the leak to that segment. This allows other zones to continue operating normally, maintaining productivity while ensuring safety by containing the refrigerant leak to a limited area.
2Productivity
If the cooling system continues operating with refrigerant leaks, then productivity is maintained, but safety concerns arise and refrigerant concentration increases
Solution Approach 1:
Refrigerant concentration sensors continuously monitor the environment and provide feedback to the controller. When the detected refrigerant concentration exceeds a predetermined threshold, the controller automatically closes the expansion valve for that zone, stopping refrigerant flow. This feedback mechanism allows the system to maintain productivity under normal conditions while automatically responding to prevent dangerous refrigerant accumulation.
Solution Approach 2:
The system dynamically adjusts its operation based on real-time refrigerant concentration levels. The expansion valves are controlled dynamically - open during normal operation to maintain productivity, and closed automatically when sensors detect elevated refrigerant concentrations. This dynamic control allows the system to adapt between maintaining productivity and preventing safety hazards.
3Reliability
If refrigerant flow is stopped by closing the expansion valve, then leak isolation is achieved and safety is improved, but cooling capacity to the load is reduced
Solution Approach 1:
The system segments the cooling load into multiple zones, each controlled by its own expansion valve. When a leak is detected in one zone, only that zone's expansion valve is closed, isolating the refrigerant leak while allowing other zones to continue receiving cooling capacity. This segmentation minimizes the impact on overall cooling capacity while achieving effective leak isolation.
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 enables the detection, isolation, and management of refrigerant leaks within the cooling system, preventing system-wide shutdowns and ensuring safety by expelling leaked refrigerant, thus minimizing operational disruptions and maintaining space safety.
Implementation Method 1
a sensor detects a concentration of the refrigerant in the space
Implementation Method 2
The expansion valve cools a refrigerant
Implementation Method 3
The exhaust system evacuates the refrigerant from the space
Data Source
Figure 1
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AI summary
An apparatus (100) includes an expansion valve (205), a load (110), a sensor (210), an exhaust system (215), and a controller (125). The expansion valve (205) cools a refrigerant. The load (110) uses the refrigerant to cool a space (115). The sensor (210) detects a concentration of the refrigerant in the space (115). The exhaust system (215) evacuates the refrigerant from the space (115). The controller (125) determines whether the detected concentration of the refrigerant in the space (115) exceeds a first threshold and in response to a determination that the detected concentration of the refrigerant exceeds the first threshold, closes the expansion valve (205). The controller (125) also determines whether the detected concentration of the refrigerant in the space (115) exceeds a second threshold and in response to a determination that the detected concentration of the refrigerant exceeds the second threshold, activates the exhaust system (215).