Vacuum System Load-Switched Heat Exchange for Lower Idle Power
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Solution Overview
Problem
Existing vacuum systems consume excess power during idle or low load conditions due to cooling blocks acting as heat sinks, delaying the pump's target operating temperature and increasing power consumption.
Innovation Solution
A vacuum system with a heat exchanger and control valves that regulate heat transfer fluid supply based on pump load, allowing bypassing the heat exchanger during low loads and utilizing a cooling block for additional cooling during high loads, reducing thermal energy absorption and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling block is used to maintain pump temperature during high load operation, then the pump temperature is maintained, but during low load operation the cooling block acts as a heat sink and delays the pump from reaching target operating temperature, increasing power consumption
Solution Approach 1:
The system dynamically switches between cooling block mode and heat exchanger mode based on pump load conditions. During high load operation, the cooling block actively cools the pump. During low load operation, the heat exchanger replaces the cooling block to prevent excessive heat sinking, allowing the pump to reach target temperature faster and reducing power consumption.
Solution Approach 2:
The system changes the thermal parameter of the heat transfer path by switching between two different heat transfer devices (cooling block and heat exchanger) with opposite thermal characteristics. The cooling block provides active cooling with higher heat transfer coefficient during high load, while the heat exchanger provides passive heat rejection with lower heat sinking during low load, optimizing temperature control across different operating conditions.
2Stability of the object's composition
If the cooling block continuously operates to maintain target temperature, then temperature stability is improved, but the system footprint increases and additional power is consumed during low load conditions
Solution Approach 1:
The system uses dynamic control to switch between cooling block and heat exchanger based on operational requirements. The cooling block is activated only when high cooling demand exists (high load), while the heat exchanger handles low load conditions, optimizing both temperature stability and system footprint by avoiding continuous operation of the larger cooling block.
3Use of energy by moving object
If the heat exchanger operates during low load conditions, then thermal energy absorption is reduced and power consumption decreases, but temperature control precision may be compromised
Solution Approach 1:
The system dynamically selects the appropriate heat transfer device based on load conditions. The heat exchanger is used during low load conditions where its lower heat sinking characteristic reduces power consumption, while the cooling block is used during high load conditions where precise temperature control is more critical, thus optimizing both energy efficiency and temperature control precision across different operating ranges.
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 system achieves faster temperature regulation and reduced power consumption by optimizing heat rejection, minimizing the need for cooling blocks and gas heaters, thus enhancing efficiency and reducing system footprint.
Implementation Method 1
The heat exchanger may be thermally coupled to the pump housing. The heat exchanger may be mounted to the pump housing. A thermal coupler may be provided between the heat exchanger and the heat exchanger to promote thermal conduction.
Implementation Method 2
In use, the heat transfer fluid introduced through the inlet follows the flow path and is discharged through the outlet. The flow path may, for example, comprise or consist of a serpentine path or a convoluted path to increase the heat exchange surface area.
Implementation Method 3
The vacuum pumps are equipped with cooling blocks to maintain the pump temperature during such an event. However, when the vacuum pump is operating at low loads, for example during idle operating conditions, the cooling block functions as a heat sink which absorbs thermal energy.
Implementation Method 4
The vacuum system may comprise a gas heater for heating the heat transfer fluid. The gas heater may, for example, be disposed between the heat exchanger and the port. The heat transfer fluid discharged from the heat exchanger may be supplied to the gas heater.
Data Source
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AI summary
Aspects of the present invention relate to a vacuum system (1). The vacuum system (1) includes a vacuum pump (3); and a heat exchanger (7) for receiving a heat transfer fluid. The heat transfer fluid comprising a gas. The heat exchanger (7) is thermally coupled to the vacuum pump (3) and is operable to absorb thermal energy from the vacuum pump (3). Aspects of the present invention also relate to a method of operating a vacuum system (1); and a controller (31) for controlling operation of a vacuum system (1).