Single-Module HVACR Controller for Multi-System Energy Optimization
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Solution Overview
Problem
Current HVACR systems lack comprehensive energy optimization, primarily focusing on compressor power consumption without addressing peak demand, and are limited by biofilm growth on cooling coils which reduces efficiency and increases energy usage.
Innovation Solution
A modular optimizing controller that controls refrigerant circulation, water flow, air flow, refrigerant temperature, and compressor operation, combined with a coil treatment using enzymatic cleaning and biostatic coatings to prevent biofilm growth, allowing for simultaneous control of multiple HVACR systems and reducing energy usage by over 15%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single controller is designed to control multiple types of HVACR systems, then versatility and adaptability are improved, but device complexity increases
Solution Approach 1:
The controller is designed with universal communication capabilities that allow it to interface with multiple types of HVACR systems (DX, chilled water, VRF, heat pumps) through standardized protocols. The controller can selectively activate different control algorithms and parameters based on the detected system type, enabling one device to perform multiple control functions without requiring separate dedicated controllers for each system type.
Solution Approach 2:
The controller architecture is divided into modular functional sections: a communication interface module for detecting system type and establishing protocols, a control algorithm module that can be selectively activated, and aactuator control module. This segmentation allows the controller to enable only the necessary functional sections for each specific HVACR system type, reducing the effective complexity for each control task while maintaining overall versatility.
2Use of energy by moving object
If comprehensive system optimization is implemented controlling multiple parameters, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The controller dynamically adjusts its control strategy based on real-time system conditions and detected HVACR system type. It can selectively activate different control algorithms (e.g., temperature-based control, pressure-based control, flow-based control) and adjust the number and type of actuators controlled according to the specific system configuration. This dynamic adaptation allows comprehensive optimization of energy consumption without requiring all control functions to be permanently active, thereby managing complexity.
Solution Approach 2:
The controller changes operational parameters such as communication protocols, control algorithms, and actuator settings based on the detected HVACR system type. For example, it may use temperature differential control for DX systems, flow rate control for chilled water systems, or pressure control for VRF systems. This parameter adaptation enables energy optimization specific to each system type without requiring a completely different controller design for each.
3Loss of energy
If biofilm prevention treatment is applied to cooling coils, then heat exchange efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The biostatic coating is applied to the cooling coils during the manufacturing process before the coils are installed in the HVACR system. This preliminary application ensures that the protective coating is in place before the coils encounter operating conditions that would promote biofilm growth. The coating serves as a pre-established barrier that prevents biofilm adhesion and growth throughout the coil's service life, eliminating the need for complex maintenance treatments later.
Solution Approach 2:
The cooling coils are manufactured with a composite structure that integrates the base metal material with a biostatic coating layer. This composite construction combines the thermal conductivity benefits of metal with the biofilm-prevention properties of the coating material. The integrated manufacturing process applies the coating as part of the coil production, creating a unified component that achieves both heat exchange efficiency and biofilm resistance without requiring separate complex treatment steps.
Data Source
AI summary
Described herein is a single unit optimizing controller (100) capable of operating any known type of heating, ventilation, air conditioning and refrigeration HVACR system (an HVACR system is denote by reference numeral (101)), which include all ACR systems. HVACR system (101) takes the form of an air conditioning unit. The controller includes a communications section (102) for communicating with one or more remote controller terminal in the form of a web application (103) and a control section (104). The air conditioning unit of HVACR system (101) includes at least one cooling unit having a compressor wherein the control section is operatively associated with HVACR system (101) for selectively activating or deactivating the at least one cooling unit based on one or more settings received from web application (103) via communications section (102).