Variable-Speed Compressor Ice Maker for Adaptive Cooling Load Control
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Solution Overview
Problem
Conventional ice makers have inefficient refrigeration systems due to oversized components that operate at fixed speeds, leading to reduced efficiency and higher pressure differentials throughout the cooling cycle, particularly during the latent cooling phase.
Innovation Solution
The implementation of a variable-speed compressor, condenser fan, and water pump, controlled by a controller that adjusts speeds based on the state of the cooling cycle, including sensible and latent cooling phases, to optimize refrigerant mass flow and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed-speed compressor and condenser fan are used, then device complexity is reduced, but energy efficiency deteriorates due to mismatched operating speeds during different cooling phases
Solution Approach 1:
The patent applies dynamics by transitioning from fixed-speed components to variable-speed components that can adapt their operating characteristics in real-time. The compressor and condenser fan are equipped with variable-speed drives that allow continuous adjustment of rotational speed based on the refrigeration load requirements during different cooling phases (sensible cooling, latent cooling, and harvest cycles), thereby resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The patent implements parameter changes by modifying the operating parameters (rotational speed) of the compressor and condenser fan. During sensible cooling, both operate at high speed; during latent cooling, speeds are reduced; and during harvest cycles, speeds are adjusted accordingly. This dynamic parameter adjustment enables the system to adapt to varying refrigeration loads while managing the complexity through controlled parameter variation.
2Power
If oversized compressor is used, then refrigeration capacity is sufficient for maximum load, but energy efficiency deteriorates during low-load latent cooling phase
Solution Approach 1:
The variable-speed compressor enables dynamic adjustment of refrigeration capacity to match the actual load requirements. During the latent cooling phase when refrigeration load is lower, the compressor speed is reduced accordingly, allowing the oversized compressor to operate efficiently at partial load rather than running at full capacity, thus resolving the contradiction between sufficient refrigeration capacity and energy efficiency during low-load conditions.
Solution Approach 2:
The patent applies partial action by operating the oversized compressor at reduced capacity during latent cooling and harvest phases. Rather than running the compressor at full power continuously, the system uses partial capacity operation matched to the actual refrigeration needs, thereby reducing energy consumption while maintaining sufficient refrigeration capacity when required.
3Adaptability or versatility
If fixed-speed condenser fan is used, then device complexity is minimized, but energy efficiency deteriorates due to inability to match condensing conditions
Solution Approach 1:
The variable-speed condenser fan applies dynamics by enabling continuous adjustment of fan speed to match condensing conditions. During high-heat rejection periods, the fan operates at high speed; during moderate conditions, speed is reduced. This dynamic response allows the system to adapt to varying condensing conditions while managing complexity through coordinated control with the compressor speed adjustments.
4Power
If high refrigerant mass flow is maintained throughout cycle, then cooling capacity is sufficient for all phases, but energy efficiency deteriorates during latent cooling and harvest
Solution Approach 1:
The variable-speed compressor and condenser fan work together to dynamically adjust refrigerant mass flow to match the refrigeration load. During sensible cooling, high refrigerant mass flow is maintained for maximum cooling capacity. During latent cooling and harvest phases when load is reduced, the system decreases refrigerant mass flow by reducing compressor speed and condenser fan speed, thereby preventing energy waste while maintaining sufficient cooling capacity when needed.
Solution Approach 2:
The patent implements parameter changes by adjusting refrigerant mass flow parameters according to the cooling phase. The system transitions from high refrigerant mass flow during sensible cooling to reduced refrigerant mass flow during latent cooling and harvest, optimizing the balance between cooling capacity and energy efficiency through controlled parameter variation.
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 enhances energy efficiency and reduces operational costs by matching component speeds to the varying refrigeration loads throughout the cooling cycle, improving overall ice production efficiency.
Implementation Method 1
a variable-speed compressor, a condenser, and an evaporator, wherein the variable-speed compressor, the condenser, and the evaporator are in fluid communication by one or more refrigerant lines. A refrigerant flows through the one or more refrigerant lines.
Implementation Method 2
a variable-speed compressor, a condenser, and an evaporator, wherein the variable-speed compressor, the condenser, and the evaporator are in fluid communication by one or more refrigerant lines
Implementation Method 3
a variable-speed compressor, a condenser, and an evaporator, wherein the variable-speed compressor, the condenser, and the evaporator are in fluid communication by one or more refrigerant lines. A refrigerant flows through the one or more refrigerant lines.
Implementation Method 4
The evaporator is thermally coupled to the freeze plate in order to freeze the supplied water into ice
Implementation Method 5
the supplied water begins to freeze in the freeze plate, the latent cooling cycle begins and the amount of water falling from the freeze plate back to the water pump decreases slightly as ice is formed on the freeze plates
Implementation Method 6
a water pump for supplying water to the freeze plate
Implementation Method 7
a freeze plate thermally coupled to the evaporator
Implementation Method 8
the supplied water is continuously recirculated across the freeze plate and back to the water pump thereby cooling the supplied water
Data Source
AI summary
An ice maker for forming ice during a cooling cycle, the ice maker having a variable-speed compressor, a condenser, and an evaporator, wherein the variable-speed compressor, the condenser, and the evaporator are in fluid communication by one or more refrigerant lines. The ice maker further includes a freeze plate thermally coupled to the evaporator, a water pump, a sensing device for identifying a state of the cooling cycle, and a controller adapted to control the speed of the variable-speed compressor based on the identified state of the cooling cycle. The ice maker may also include a variable-speed condenser fan which may be controlled by the controller based on the identified state of the cooling cycle. Additionally, the water pump may be a variable-speed water pump which may be controlled by the controller based on the identified state of the cooling cycle.