Refrigeration system with condenser temperature differential setpoint control
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Solution Overview
Problem
Existing refrigeration systems for temperature-controlled display devices are inefficient as they fail to account for the characteristics of the liquid coolant, leading to unnecessary energy consumption and operational stress when trying to achieve a refrigerant condensing setpoint that is physically impossible due to the coolant's temperature.
Innovation Solution
A refrigeration system with a controller that modulates the flow of coolant through the condenser to maintain a coolant temperature differential setpoint, using a separate cooling circuit with a pump, control valve, and heat removing device, and adjusts the operation of the compressor and expansion device to maintain desired temperatures, preventing excessive energy use and operational stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the controller operates the liquid cooling system at maximum capacity to achieve a refrigerant condensing setpoint, then the refrigerant condensing temperature control is improved, but the energy consumption increases and the system experiences unnecessary operational stress
Solution Approach 1:
The patent changes the control parameter from a fixed refrigerant temperature setpoint to a variable setpoint that adapts to coolant temperature conditions. When coolant temperature is high, the system accepts a higher refrigerant condensing temperature rather than operating at maximum capacity, thereby reducing energy consumption and operational stress while maintaining acceptable refrigeration performance.
Solution Approach 2:
The system transitions from static maximum-capacity operation to dynamic operation that adjusts cooling system capacity based on real-time coolant temperature conditions. The controller modulates the cooling system operation to match actual thermal demands, avoiding unnecessary high-capacity operation when coolant temperature makes low-temperature condensing physically unattainable.
2Temperature
If the controller operates the liquid cooling system at maximum capacity, then the refrigerant condensing temperature control is improved, but the system reliability deteriorates due to unnecessary operational stress
Solution Approach 1:
The system dynamically adjusts operating capacity based on coolant temperature conditions, avoiding sustained maximum-capacity operation that causes operational stress. By modulating the cooling system operation to match actual thermal demands, the system maintains reliability while achieving adequate refrigerant condensing temperature control.
Solution Approach 2:
The patent applies partial action by operating the cooling system at reduced capacity when coolant temperature conditions make maximum capacity unnecessary. The controller determines that partial cooling capacity is sufficient when coolant temperature is high, avoiding the excessive operational stress that would compromise system reliability.
3Ease of operation
If the controller uses a fixed refrigerant temperature setpoint, then the temperature control simplicity is maintained, but the adaptability to coolant temperature conditions deteriorates
Solution Approach 1:
The control system transitions from a fixed static setpoint to a dynamic setpoint that automatically adapts to coolant temperature conditions. The controller calculates an adjusted refrigerant condensing temperature setpoint based on measured coolant temperature, maintaining control simplicity through automated adaptation rather than complex manual adjustments or multiple fixed setpoints.
Solution Approach 2:
The patent changes the control parameter from a fixed temperature value to a variable setpoint that is dynamically determined based on coolant temperature. This parameter change enables the system to adapt to varying coolant conditions while maintaining the simplicity of single-loop temperature control architecture.
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 enhances the efficiency of the refrigeration system by ensuring the coolant temperature differential is maintained within set limits, reducing energy consumption and preventing operational overloads, thereby improving the overall performance and reliability of the refrigeration process.
Implementation Method 1
a heat removing device in fluid communication with the condenser via the coolant
Implementation Method 2
cooled/condensed to a lower temperature state (e.g., in a gas cooler or condenser which absorbs heat from the refrigerant)
Implementation Method 3
evaporated to provide cooling by absorbing heat into the refrigerant
Data Source
AI summary
A refrigeration system for a temperature-controlled storage device includes a refrigeration circuit that circulates a refrigerant, a separate cooling circuit that circulates a coolant, and a controller. The refrigeration circuit includes a compressor, a condenser, an expansion device, and an evaporator. The cooling circuit includes a pump, a control valve, and a heat removing device in fluid communication with the condenser via the coolant. The controller is operatively coupled to the control valve and configured to identify a coolant temperature differential setpoint, monitor a temperature of the coolant provided to the condenser by the cooling circuit, calculate a coolant temperature differential based on the temperature of the coolant provided to the condenser, and operate the control valve to modulate a flow of the coolant through the condenser to drive the coolant temperature differential to the coolant temperature differential setpoint.