Refrigerated Dryer Flow-Based Compressor Shutdown for Power Savings
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Solution Overview
Problem
Conventional refrigerated dryers for gas compressor systems consume excessive power due to continuous operation of the refrigerant compressor, even when there is no cooling demand, and cyclic dryers are costly and complex.
Innovation Solution
A control system that includes a controller, flow sensor, and temperature sensor to selectively operate in a power-saving mode, shutting down the refrigerant compressor when no compressed gas is flowing and activating it based on temperature conditions, allowing for efficient operation similar to both non-cyclic and cyclic dryers without the added cost and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the refrigerant compressor operates continuously to provide continuous cooling, then the compressed gas is continuously dried, but power consumption increases significantly
Solution Approach 1:
The system dynamically adjusts the compressor operation mode based on real-time demand conditions. When gas flow is detected, the system switches to active cooling mode with continuous compressor operation. When no gas flow is detected, the system transitions to standby mode with compressor shutdown, thereby adapting the system behavior to actual operational needs and avoiding unnecessary energy consumption.
Solution Approach 2:
The system changes the operational parameters of the compressor based on demand conditions. The compressor operates at full capacity when cooling demand exists, but is completely shut down when demand is absent. This parameter change from continuous operation to on-demand operation resolves the contradiction between reliable continuous drying and excessive power consumption.
2Use of energy by moving object
If the refrigerant compressor is shut down to save power, then power consumption decreases, but the drying function cannot be provided when needed
Solution Approach 1:
The system employs feedback control through flow sensors that continuously monitor gas flow conditions and provide real-time information to the controller. This feedback mechanism enables the system to detect when compressed gas is present and automatically activate the compressor, and to detect when gas flow has ceased and shut down the compressor, ensuring the drying function is available precisely when needed while avoiding unnecessary operation.
Solution Approach 2:
The system performs preliminary detection of gas flow conditions before activating or deactivating the compressor. The flow sensors continuously monitor the presence of compressed gas, and the controller is pre-programmed with activation/shutdown logic that executes automatically upon detecting appropriate conditions, ensuring rapid response when drying demand arises.
3Use of energy by moving object
If a cold sink is added to enable cyclic operation, then power consumption decreases, but device complexity and cost increase
Solution Approach 1:
The invention extracts and eliminates the cold sink component from the traditional cyclic dryer system. By removing this expensive and complex thermal energy storage element, the system achieves cyclic operation through a different mechanism: using flow-based control to shut down the compressor entirely when no cooling demand exists, rather than using a cold sink to store thermal energy for later use.
Solution Approach 2:
The system copies the essential functional outcome of cyclic dryers (reduced power consumption through periodic operation) without copying their complex structure. Instead of implementing a cold sink and associated control systems, the invention uses a simplified flow-sensor-based controller that achieves similar energy savings through demand-based compressor shutdown, replicating the benefit without the complexity.
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 power-saving mode significantly reduces power consumption and wear on components, achieving nearly 95% power savings compared to normal operation under zero load conditions while maintaining reliability and performance similar to cyclic dryers.
Implementation Method 1
the controller shuts down a refrigerant compressor included in the dryer system when a flow sensor indicates that no compressed gas is flowing through the dryer
Implementation Method 2
The control system may use input from a temperature sensor to determine whether to activate the compressor regardless of the flow of compressed gas through the dryer
Implementation Method 3
refrigerated dryers use a refrigeration circuit to remove moisture from the compressed gas by cooling the gas to cause the moisture vapor in the gas to condense and separate from the compressed gas
Data Source
AI summary
Methods are provided for controlling a refrigerated dryer of a gas compressor system. In an aspect, a control system, including a controller and a flow sensor, selectively operates in a power saving mode in which the controller shuts down a refrigerant compressor included in the dryer system when the flow sensor indicates that no compressed gas is flowing through the dryer. The control system uses input from a temperature sensor to determine whether to activate the compressor regardless of the flow of compressed gas through the dryer.