System and method for controlling temperature at test sites
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Solution Overview
Problem
Existing temperature control systems for multiple test sites are inefficient and space-consuming, with significant thermal loss and high costs due to the need for individual temperature control at each site and the use of expensive, inflexible piping for chilled air distribution.
Innovation Solution
A centralized temperature control system that generates a chilled fluid stream and dry air stream, which are distributed to remote test stations via heat exchangers, allowing for precise temperature control and efficient cooling without the need for expensive piping, using a closed-loop chilled fluid system and a separate air dryer to ensure dry air for testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a centralized cold air source is used to deliver cooled air to remote test stations, then space is saved and cost is reduced, but thermal loss increases and temperature control precision deteriorates
Solution Approach 1:
The patent introduces a chilled fluid (liquid nitrogen or refrigerant) as an intermediary carrier to transport cooling capacity from the centralized chiller to remote test stations. This liquid intermediary maintains thermal efficiency better than direct air transport over long distances, resolving the contradiction between centralized space savings and thermal loss.
Solution Approach 2:
The system uses hydraulic principles by circulating chilled liquid through closed-loop piping to test stations. This liquid-based thermal transport system efficiently carries cooling energy over distance with minimal thermal loss compared to compressed air systems, addressing both space consolidation and energy loss concerns.
2Loss of energy
If vacuum jacketed hoses are used to transport chilled air, then thermal loss is reduced, but system cost increases and flexibility decreases
Solution Approach 1:
The patent employs standard, inexpensive piping materials (copper, stainless steel, or insulated plastic tubes) instead of expensive vacuum jacketed hoses. The system achieves adequate thermal performance with simpler, more flexible, and lower-cost piping that can be easily routed and installed.
Solution Approach 2:
The system changes the physical state parameter of the cooling medium from gas (chilled air) to liquid (chilled fluid). This phase change enables efficient heat transfer through conventional piping without requiring vacuum insulation, reducing both cost and improving installation flexibility while maintaining low thermal loss.
3Area of stationary object
If chilled air is distributed through piping to multiple test stations, then centralized cooling is achieved, but the system takes long to cool down piping and delays testing
Solution Approach 1:
The system pre-cools the liquid nitrogen or refrigerant in the centralized chiller before distribution. Additionally, the liquid piping system is pre-chilled during operation, and the high thermal conductivity of liquid enables rapid cooling of test station components, eliminating the long warm-up delays associated with large-volume chilled air systems.
Solution Approach 2:
The system utilizes phase transition of liquid nitrogen or refrigerant to efficiently transfer thermal energy. The liquid phase enables high heat capacity and rapid heat transfer, allowing quick cooling of test stations without the thermal mass delays inherent in gas-phase air cooling systems.
4Measurement precision
If precise temperature control is achieved at each test site, then testing accuracy is improved, but system complexity and cost increase
Solution Approach 1:
The chilled liquid acts as an efficient thermal intermediary that maintains stable, precise temperatures during transport. Combined with localized heat exchangers and temperature sensors at each test station, this enables precise temperature control through a relatively simple centralized system architecture.
Solution Approach 2:
The system incorporates temperature sensors at test stations that provide feedback to the centralized chiller controller. This closed-loop feedback enables precise temperature regulation at remote locations while maintaining system simplicity through centralized control logic.
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 conserves space, reduces costs, and improves efficiency by allowing multiple test sites to share a single chiller and air dryer, enabling precise temperature control and flexible temperature adjustments at each site without the need for expensive piping, while minimizing thermal loss and equipment noise.
Implementation Method 1
The heat exchanger is configured to selectively cool the dry air stream with the chilled fluid stream to generate an output stream
Data Source
AI summary
A temperature control system includes a fluid chiller, an air dryer, and a plurality of test stations positioned at remote locations from the fluid chiller and the air dryer. The fluid chiller is configured to generate a chilled fluid stream. The air dryer is configured to generate a dry air stream. Each local test station includes a heat exchanger and thermal control unit. The heat exchanger is configured to selectively cool the dry air stream with the chilled fluid stream to generate an output stream. The thermal control unit is configured to control distribution of the output stream to a local test site.