Thermoelectric Chamber Cooling with Segmented TEC Control
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Solution Overview
Problem
Vapor compression based refrigeration systems face inefficiencies in controlling temperature within a cooling chamber, leading to excessive wear and sub-optimal performance due to large current surges and difficulty in precisely managing cooling capacity, which results in reduced efficiency and premature component failure.
Innovation Solution
A thermoelectric refrigeration system with a two-phase heat exchanger mounted at an angle offset from vertical, allowing for selective control of Thermoelectric Coolers (TECs) to optimize heat flux and efficiency, and a controller that independently manages subsets of TECs to maintain a set point temperature, thereby enhancing cooling capacity and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If vapor compression based refrigeration systems use duty cycle control to manage cooling capacity, then the system can operate in varied ambient conditions, but large current surges occur during start-up and operation causing excessive wear and component failure
Solution Approach 1:
The system divides the TEC array into multiple independently controllable subsets or groups. Each subset can be activated or deactivated separately based on cooling demand, allowing the system to provide fine-grained capacity modulation without large current surges. This segmentation enables smooth transitions between operating levels and eliminates the need for duty cycling entire arrays, thereby extending component lifespan while maintaining adaptability to varied ambient conditions.
2Use of energy by moving object
If vapor compression based refrigeration systems activate cooling when temperature exceeds a certain value and shut off when below, then energy consumption is minimized, but temperature control precision is poor with large control bands and internal temperature stratification
Solution Approach 1:
The TEC array is divided into multiple subsets that can be independently controlled. By activating only the necessary number of subsets based on precise temperature sensing, the system maintains tight temperature control with minimal control bands. This granular control capability allows the system to operate continuously at low power levels rather than cycling on and off, thereby achieving both energy efficiency and high temperature precision simultaneously.
Solution Approach 2:
The system dynamically adjusts the number of active TEC subsets based on real-time temperature feedback and cooling demand. This dynamic modulation allows continuous adaptation to maintain the set point temperature with high precision while minimizing energy consumption by activating only the necessary cooling capacity at any given moment.
3Productivity
If vapor compression based refrigeration systems increase cooling capacity to meet transient demand during pull down or recovery, then pull down performance is improved, but large current surges are required causing expensive components and excessive wear
Solution Approach 1:
The system uses segmented TEC subsets that can be progressively activated during pull-down or recovery operations. Instead of applying full cooling capacity immediately causing large current surges, the system activates subsets in sequence or at staggered intervals, providing the necessary high cooling capacity for rapid temperature reduction while limiting peak current demands and reducing component stress and wear.
4Ease of manufacture
If two-phase heat exchanger is mounted vertically, then installation is simple, but heat transfer efficiency is reduced because working fluid does not directly impinge on highest heat flux region
Solution Approach 1:
The heat exchanger is mounted at an asymmetric angle offset from vertical rather than in a simple vertical position. This asymmetric orientation is specifically designed so that the working fluid flow path directs the fluid to directly impinge on the highest heat flux region of the heat exchanger surface. This asymmetric mounting configuration optimizes heat transfer efficiency by ensuring maximum thermal contact between the working fluid and the most thermally active areas, thereby reducing energy loss while maintaining reasonable installation complexity.
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 solution improves the efficiency of the refrigeration system by optimizing heat transfer and reducing wear on components, allowing for precise temperature control and increased cooling capacity while minimizing energy consumption and extending component lifespan.
Implementation Method 1
mounting of a two-phase heat exchanger within a thermoelectric system
Implementation Method 2
the working fluid is forced to directly impinge on a highest heat flux region within the two-phase heat exchanger
Implementation Method 3
a cartridge including multiple thermoelectric coolers (TECs)... selectively controlling two or more subsets of TECs in the plurality of TECs
Data Source
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AI summary
Embodiments of the present disclosure relate to controlling multiple Thermoelectric Coolers (TECs) to maintain a set point temperature of a chamber. In one embodiment, a controller receives temperature data corresponding to a temperature of the chamber. Based on the temperature data, the controller selectively controls two or more subsets of the TECs to maintain the temperature of the chamber at a desired set point temperature. In this manner, the controller is enabled to control the TECs such that the TECs operate to efficiently maintain the temperature of the chamber at the set point temperature. In another embodiment, the controller selects one or more control schemes enabled by the controller based on temperature data and a desired performance profile. The controller then independently controls one or more subsets of the TECs according to the selected control scheme(s).