System for coordinated flow control of fluids through a heat exchanger
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Solution Overview
Problem
Conventional heat exchanger systems face inefficiencies in temperature control due to independent control loops, leading to increased wear and system cycling, which affects performance and lifespan.
Innovation Solution
A coordinated flow control method and system that utilizes a variable actuator and a discrete actuator, controlled by a controller to adjust their positions within predetermined ranges, ensuring efficient heat exchange by minimizing errors between desired and actual temperatures, thereby reducing system wear and cycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If independent control loops are used to control fluid flows in heat exchanger systems, then each control loop can operate autonomously, but system wear increases and cycling frequency increases
Solution Approach 1:
The patent combines multiple independent control loops into a coordinated control system where a master controller synchronizes the operation of multiple actuators. This merging approach maintains autonomous control capabilities while reducing overall system cycling by coordinating actuator operations to avoid frequent switching, thereby reducing wear and improving reliability.
Solution Approach 2:
The control system dynamically adjusts actuator positions based on real-time temperature measurements and system state. By continuously optimizing actuator positions rather than using fixed independent control, the system reduces unnecessary cycling while maintaining effective temperature control, thus reducing wear on mechanical components.
2Adaptability or versatility
If multiple separate controllers are used to control valves and fans, then each component can be controlled independently, but control system complexity increases
Solution Approach 1:
The patent implements a universal master controller that can control multiple different types of actuators (valves, fans, etc.) through a unified control architecture. This multi-functional controller maintains the ability to independently control each component while reducing overall system complexity by eliminating the need for separate dedicated controllers for each component.
Solution Approach 2:
Multiple separate controllers are merged into a single coordinated control system. The master controller integrates the control functions for multiple components, reducing the number of separate control devices while maintaining independent control capability through software-based control strategies and coordinated actuator management.
3Ease of manufacture
If conventional independent control loops are used, then implementation is simple, but temperature control accuracy decreases
Solution Approach 1:
The coordinated control system incorporates feedback from temperature sensors to continuously monitor system performance and adjust actuator positions accordingly. This feedback mechanism improves temperature control accuracy by detecting deviations from setpoints and making real-time corrections, while the control logic remains implementable through standard control algorithms.
Solution Approach 2:
The control system performs preliminary calculations to determine optimal actuator positions based on current system state and desired temperature setpoints. By pre-calculating the required adjustments and coordinating multiple actuators to move to their target positions simultaneously, the system achieves better temperature control accuracy while maintaining relatively simple implementation through algorithmic control.
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
The coordinated flow control method improves temperature control accuracy, reduces system wear, and enhances performance by optimizing actuator positions and minimizing energy consumption, leading to improved system efficiency and extended lifespan.
Implementation Method 1
heat exchanger
Implementation Method 2
fluid flows for heat exchange
Data Source
AI summary
A system includes a heat exchanger; a variable actuator in operative communication with the heat exchanger and configured to vary a flow of a first fluid through the heat exchanger in a continuous manner; a discrete actuator in communication with the heat exchanger and configured to vary a flow of a second fluid through the heat exchanger at one of at least two discrete rates; and a controller in communication with the variable actuator and the discrete actuator, wherein the controller is configured to adjust the position of the variable actuator within a range dependent upon a current position of the discrete actuator.