Refrigeration system with superheating, sub-cooling and refrigerant charge level control
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Solution Overview
Problem
Conventional refrigeration systems lack solutions for maintaining optimal refrigerant charge levels, leading to inefficiencies and safety issues when the refrigerant level falls below a predetermined threshold.
Innovation Solution
A refrigeration system with sensors to measure sub-cooling and super-heating levels, a controller to determine and maintain the refrigerant charge level, and an electronic valve to refill refrigerant when necessary, ensuring the system operates efficiently and safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional refrigeration systems only determine refrigerant charge level without refill capability, then the system structure remains simple, but the system reliability deteriorates when refrigerant level falls below threshold
Solution Approach 1:
The refrigeration system automatically refills refrigerant when the charge level falls below a threshold. The controller monitors refrigerant charge level and activates the electronic valve to open, allowing refrigerant to flow from the reservoir into the refrigerant circuit, eliminating the need for manual intervention and maintaining continuous operational reliability
Solution Approach 2:
A refrigerant reservoir is pre-filled with sufficient refrigerant charge before system operation. This preliminary preparation ensures that when refrigerant level in the circuit drops, the refill function can immediately restore adequate charge levels without external intervention, maintaining system reliability
2Reliability
If refrigerant charge level is not maintained, then operational time extends without maintenance, but system efficiency and safety deteriorate
Solution Approach 1:
The controller continuously monitors refrigerant charge level and provides feedback control. When the charge level falls below a predetermined threshold, the controller activates the electronic valve to refill refrigerant from the reservoir, maintaining charge levels within optimal ranges for system safety and efficiency throughout extended operational periods
3Productivity
If manual refrigerant top-up is required, then device complexity remains low, but loss of time increases due to frequent maintenance interruptions
Solution Approach 1:
The system automatically monitors refrigerant charge level and performs refill operations without manual intervention. The controller detects when charge level drops below threshold and activates the electronic valve to transfer refrigerant from the reservoir, eliminating maintenance interruptions and maximizing operational continuity
Solution Approach 2:
The refrigerant reservoir is pre-charged with sufficient refrigerant capacity to cover extended operational periods. This preliminary preparation allows the automatic refill function to maintain continuous operation without external service interventions, eliminating maintenance time losses
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 system effectively predicts and maintains optimal refrigerant levels, preventing failures, extending operational time, and allowing for scheduled maintenance, thus enhancing efficiency and safety.
Implementation Method 1
The compressor compresses a refrigerant
Implementation Method 2
The condenser, disposed downstream of the compressor, condenses the refrigerant
Implementation Method 3
The evaporator, disposed downstream of the condenser, vaporizes the refrigerant
Implementation Method 4
The receiver drier is configured to temporarily store the refrigerant or absorb moisture from the refrigerant
Data Source
AI summary
The refrigeration system includes a compressor, a condenser, an evaporator, one or both of a receiver drier unit and an accumulator unit fluidly connected by refrigerant lines to form a refrigerant circuit. The receiver drier unit includes a receiver drier and a first sensor, and the accumulator unit includes an accumulator and a second sensor. A controller is electrically connected to the first and second sensors and in some cases electrically connected to an electrical valve. The electrical valve is fluidly connected to a refrigerant reservoir. The controller determines the refrigerant charge level, and selectively controls the electrical valve to allow the refrigerant to flow from the refrigerant reservoir to the refrigerant circuit when the refrigerant charge level is below the predetermined refrigerant charge level.