Submersible Mixing Chamber Layout for Precise Temperature Control
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Solution Overview
Problem
Existing tempering devices using mixing valve technology face inefficiencies in heat distribution and require extensive external piping, leading to operational reliability issues and increased energy consumption.
Innovation Solution
A tempering device with a submersible mixing chamber and pump installed below the tank's filling level, coupled with a compressor cooling system and a 3/2-way valve for demand-based cooling, reduces piping needs and enhances energy efficiency by directly integrating the mixing chamber with the circulation pump and heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dry mounted horizontal pump with mechanical seals is used, then the pump can be installed outside the tank, but it suffers from susceptibility to malfunctions due to fluid media containing ethylene or glycol affecting the mechanical seals
Solution Approach 1:
The mixing chamber is directly integrated with the submersible pump to form a single combined unit. The pump housing itself serves as the mixing chamber, eliminating the need for separate mixing chambers and extensive piping connections. This merging of functions reduces the number of components and connections, thereby reducing piping complexity while improving reliability by eliminating mechanical seal exposure to corrosive fluids.
Solution Approach 2:
The submersible pump acts as an intermediary element that is completely immersed in the fluid medium within the tank. By placing the pump directly in the fluid environment, it eliminates the need for mechanical seals that would otherwise be exposed to corrosive fluids containing ethylene or glycol. The pump runs entirely submerged, using the fluid environment itself as the sealing medium, thereby improving operational reliability.
2Ease of manufacture
If extensive external piping is used to connect the mixing chamber, heat exchanger, and pump, then the system can be assembled from separate components, but it increases energy consumption and operational complexity
Solution Approach 1:
The mixing chamber and pump are merged into a single integrated unit, eliminating extensive external piping. The connecting lines are minimized to only essential connections (suction inlet and pressure delivery outlet). This reduction in piping length and complexity directly reduces energy losses from friction and pressure drops, thereby lowering overall energy consumption while maintaining assembly feasibility.
Solution Approach 2:
The unnecessary intermediate piping and connection components are extracted and removed from the system. Only the essential suction inlet and pressure delivery outlet connections are retained. By taking out the excessive piping infrastructure, the system achieves lower energy consumption and reduced operational complexity while still allowing for practical assembly and installation.
3Ease of operation
If the mixing chamber is arranged above the tank filling level, then it is easier to access for maintenance, but it requires extensive external piping and reduces heat distribution efficiency
Solution Approach 1:
The mixing chamber is positioned at the same level as the pump, both completely submerged within the tank at the optimal depth for heat exchange. This equipotential positioning within the fluid medium maximizes heat distribution efficiency by eliminating height differences that would cause energy losses. The integrated design allows the entire assembly to be lifted as one unit for maintenance, preserving accessibility while optimizing thermal performance.
4Device complexity
If a submersible pump with integrated mixing chamber is used, then piping needs are reduced and heat distribution efficiency is improved, but the pump must be completely immersed in the fluid medium
Solution Approach 1:
The mixing chamber and pump are merged into a single sealed integrated unit that can be installed as one component. This merging eliminates the need for complex external piping connections, reducing piping requirements to only essential inlet and outlet connections. The integrated design simplifies installation while maximizing heat distribution efficiency through optimal positioning within the tank.
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 configuration achieves high energy efficiency, improved operational reliability, and precise temperature control with reduced piping needs, allowing for accurate temperature setting within ±0.3K and adaptable cooling capacity based on demand.
Implementation Method 1
a submersible pump (23), at least partially arranged in the tank (25), with its suction side (27) below the filling level and with its pressure delivery side (19), which leads to the feed line (15), preferably arranged above the filling level in the tank (25)
Implementation Method 2
The heat exchanger can hereby be provided in the form of a plate heat exchanger, forming a functional unit with the evaporator of the compressor cooling system
Implementation Method 3
the refrigerant flows through a heat exchanger, through which, at the same time, at least the portion of the fluid medium of the return flow to be cooled is passed
Data Source
AI summary
A temperature control device has a flow line (15) for supplying a consumer, connected to the flow line (15), with a liquid medium at a predetermined temperature. A return line (17) is connected to the consumer for returning at least one part of the liquid medium from the consumer to a mixing device (41). In a predefinable ratio, the liquid medium of the return line (17) is mixed in the mixing device with a storage medium provided in a tank (25). The mixing device has a mixing chamber (41) arranged below the filling level of the tank (25) with the storage medium.