Estimating refrigeration capacity by measuring air temperature difference and/or airflow

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Solution Overview

Problem

Existing refrigeration systems face challenges in managing refrigerant levels efficiently, leading to increased costs and space requirements due to high ammonia charges, and there is a need for systems that can reduce refrigerant usage while maintaining system performance.

Innovation Solution

A refrigeration system with a control unit that calculates instantaneous refrigeration load and adjusts refrigerant levels in the separator based on this load, using a control unit to manage the level targets and valve operations to maintain a constant refrigerant charge in the evaporator and separator, allowing for variable refrigerant levels based on capacity needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional refrigeration systems use fixed high refrigerant levels in the separator, then system reliability is maintained, but refrigerant charge increases and costs increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidrefrigerant charge

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent implements dynamic refrigerant level control in the separator by continuously adjusting the level based on actual evaporator load conditions. The control system monitors evaporator performance and modifies separator refrigerant levels accordingly, transitioning from static fixed levels to dynamic adaptive levels that match real-time system demands.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the operational parameter of separator refrigerant level from a fixed constant to a variable parameter that responds to load conditions. By adjusting the refrigerant level parameter dynamically based on evaporator feedback, the system optimizes refrigerant distribution and reduces overall charge while maintaining reliability.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If larger vessels are used to accommodate high ammonia charges, then system capacity is maintained, but space requirements increase and costs increase

Engineering Contradiction:

Improvesystem capacityVSAvoidvessel volume

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The patent enables smaller separator vessels by implementing dynamic refrigerant level control that adapts to varying load conditions. Instead of requiring oversized vessels to accommodate peak loads with fixed high levels, the system dynamically adjusts refrigerant levels to match actual demand, allowing right-sized vessel selection that reduces space requirements.

Inventive Principle:

Principle #15Dynamics

3Quantity of substance

If refrigerant levels in the separator are reduced, then refrigerant charge decreases and costs decrease, but system reliability may be compromised

Engineering Contradiction:

Improverefrigerant chargeVSAvoidsystem reliability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent implements a feedback control system that continuously monitors evaporator performance and uses this information to adjust separator refrigerant levels. The feedback mechanism ensures that refrigerant levels are maintained at optimal values for current load conditions, preventing both overcharging and undercharging, thereby maintaining system reliability while enabling reduced overall refrigerant charge.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control system automatically adjusts separator refrigerant levels based on evaporator feedback without external intervention. The system self-regulates to maintain optimal refrigerant distribution, ensuring reliability is maintained even with reduced overall charge through autonomous level management.

Inventive Principle:

Principle #25Self-service

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 approach reduces refrigerant charge by up to 55%, enhances even liquid feed control, reduces wear on components, and allows for higher operating levels at full capacity, improving efficiency and flexibility of the refrigeration system.

Implementation Method 1

air temperature difference... before and after the evaporator

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

air flow over the evaporator

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250216135A1Estimating refrigeration capacity by measuring air temperature difference and/or airflow

Publication Date: 2025.07.03 JOHN BEAN TECH AB

AI summary

A refrigeration system includes a compressor, condenser, separator, and evaporator. A condenser inlet is connected to an outlet of the compressor. A separator inlet is connected to an outlet of the condenser. An evaporator inlet is connected to a first outlet of the separator. An evaporator outlet is connected to the separator inlet. The refrigeration system includes a control unit having instructions stored thereon for executing a method comprising the steps of repetitively calculating a refrigeration load on the evaporator. and controlling a level target of refrigerant in the separator based on the calculation of the refrigeration load. In one configuration, the separator is positioned substantially laterally of the evaporator so that the refrigerant is gravity fed from the separator to the evaporator.