System and method for device under test cooling using digital scroll compressor
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Solution Overview
Problem
Existing DUT testing systems waste energy by cooling fluids to excessively low temperatures only to reheat them to the desired temperature, as they typically operate in a single mode without the ability to efficiently adjust to specific temperature requirements.
Innovation Solution
A DUT cooling system utilizing a digital scroll compressor with multiple heat exchangers and a controller that adjusts the compressor's duty cycle based on target temperature and measured variables, allowing for precise temperature control and energy-efficient operation by cooling fluids to just below the target temperature and then reheating as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the refrigeration system operates in single mode to provide maximum cooling, then the cooling capacity is improved, but energy consumption increases due to excessive cooling followed by reheating
Solution Approach 1:
The compressor operates in multiple modes (first mode for maximum cooling, second mode for reduced cooling) rather than a single fixed mode. The controller dynamically switches between modes based on the required fluid temperature, allowing the system to adapt its cooling capacity to match the actual demand and avoid excessive cooling that would require reheating.
Solution Approach 2:
The system changes the operational parameters of the compressor by switching between different modes. In the first mode, the compressor provides maximum cooling capacity; in the second mode, it provides reduced cooling capacity. This parameter change allows the system to optimize energy consumption by matching the cooling output to the actual temperature requirements.
2Temperature
If the refrigeration system cools fluid to very low temperature, then the cooling effect is improved, but temperature control precision deteriorates due to the need for reheating
Solution Approach 1:
The controller dynamically adjusts the compressor mode based on the required target temperature. When a higher temperature is needed (e.g., -40°C), the system switches to the second mode with reduced cooling capacity, cooling only to near the target temperature. This dynamic adjustment eliminates the temperature overshoot and reheating cycle, improving temperature control precision.
Solution Approach 2:
Instead of always applying full cooling capacity (excessive action), the system applies partial cooling capacity in the second mode. The compressor provides just enough cooling to reach near the target temperature without over-cooling, thereby avoiding the need for reheating and improving temperature control precision.
3Reliability
If the compressor operates continuously in maximum cooling mode, then the cooling reliability is improved, but energy efficiency deteriorates
Solution Approach 1:
The system dynamically selects between two operational modes based on the cooling demand. The controller monitors the required fluid temperature and switches the compressor between first mode (maximum cooling for high reliability) and second mode (reduced cooling for energy efficiency). This dynamic operation maintains cooling reliability when needed while improving energy efficiency when full cooling capacity is not required.
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 energy consumption by minimizing the need for excessive cooling and reheating, achieving stable and efficient fluid temperature control while optimizing energy use.
Implementation Method 1
heat exchangers arranged in succession and configured to transfer heat between a refrigerant mixture and a fluid
Implementation Method 2
heat exchangers arranged in succession and configured to transfer heat between a refrigerant mixture in the refrigerant line and a fluid in the fluid line
Implementation Method 3
scroll elements between the intake and the discharge for compressing the refrigerant mixture
Implementation Method 4
refrigerant mixture comprising a first refrigerant having a first boiling point, a second refrigerant having a second boiling point, and a third refrigerant having a third boiling point
Data Source
AI summary
A device under test cooling system has a refrigerant line and a fluid line extending through a plurality of successively arranged heat exchangers. A digital scroll compressor has an intake for providing the refrigerant mixture to the compressor and a discharge connecting the compressor to the refrigerant line to provide the refrigerant mixture to the heat exchangers. The compressor includes a plurality of scroll elements between the intake and the discharge for compressing the refrigerant mixture. The compressor includes a valve configured to separate the scroll elements when in an open position to allow refrigerant to flow freely between the intake and the discharge. When the valve is in a closed position, the scroll elements compress the refrigerant. A controller is configured to switch the valve between an open and closed position based on a set duty cycle.