Patent Application
20230070076
The invention relates to air conditioning and refrigeration system which includes an enhanced air conditioning chiller refrigeration loop to include patented stabilizer for placement between said refrigeration loop and the space/zones climate cooling air handler/handler(s) loop. More particularly, this invention relates to air conditioning and process cooling systems which includes an ice generator and storage within the chiller loop for enhanced air conditioning chiller performance, more specifically the system efficiency, which includes multiple heat transfer interactions between a conventional air conditioning refrigeration chiller circuit and the enhanced air conditioning chiller refrigeration circuit.
Heating, ventilation, and air conditioning (HVAC) and refrigeration systems, enhanced air conditioning chillers, are utilized in the cooling of domestic confined spaces/zones and process applications such as cooling electronics, chemicals, and food supplies, transferring heat from climate-controlled spaces/zones or processes to an external environment, typically to ambient air or alternatively a water source, having conditions conducive to its operation. The typical chiller system, inclusive of the enhanced air conditioning chiller, is useful for these purposes and involves a heat transfer medium, hereafter referred to as refrigerant, transitioning between gas and liquid states while circulated through its refrigerant-based components. Removal of heat gained from the compression cycle as a result of work performed by the compressor is accomplished through the system fan/coil condenser to the exterior ambient space, or alternatively another liquid medium such as water, whereupon the refrigerant gas becomes a hot liquid refrigerant through a thermodynamic process of condensing, known as a latent process. The liquid refrigerant exiting the condenser fan/coil assembly, at high pressure and temperature, is directed through a downstream patented sub-cooler, referred to as the air conditioning companion chiller stabilizer, where hot liquid refrigerant is substantially cooled. Thereby the cooled liquid refrigerant enters system expansion valve, mechanical expansion device in a traditional air conditioning chiller, or an electronic expansion valve in the enhanced air conditioning chiller, undergoing expansion resulting in the transformation of the liquid refrigerant to a very low temperature and pressure gaseous liquid composition, hereafter referred to as vapor. The refrigerant vapor then passes through the evaporator where heat is absorbed from the energy storage device, hereafter referred to as the ice storage vessel, through a secondary heat transfer medium, a hydronic solution such as glycol/water mix. Subsequently the warmer refrigerant vapor, emanating from the evaporator having undergone a quasi latent phase change resulting in superheated low temperature/pressure gas exiting the evaporator prior to re-entry to the compressor, completing the system refrigeration cycle. The reduced temperature hydronic solution leaving the system evaporator is then routed through a network of piping made possible by a hydronic pump that is controlled by a Variable Frequency Drive, or VFD, through the system control module allowing for continuous flow of hydronic solution to the ice storage vessel where heat energy is given up by its static reservoir, containing water or a brine or other solution, until such process yields ice or frozen brine solution; the storage of energy for use during the secondary chiller loop. The secondary chiller loop is dedicated to the conditioning of the spaces/zones through the fan coil heat exchanger, hereafter referred to as air handler(s), either a single air handler or an array of air handlers. The warm interior air is drawn across the integrated fan-coil assembly of the air handler(s), interfacing with the cooler hydronic solution, emanating from the ice storage vessel, absorbing the heat from the space air maintaining the space/zones climate temperature.
An enhanced air conditioning chiller system according to the present disclosure, includes a refrigeration loop containing an outdoor component comprised of a compressor and a first fan/coil condenser heat exchanger, an integrated second heat exchanger, the patented air conditioning companion stabilizer, an expansion valve, and an evaporator connected in an annular shape or form in which refrigerant circulates. An enhanced air conditioning chiller system according to present disclosure includes a hydronic solution loop containing a VFD-controlled pump, an ice storage vessel, and an air handling device with an integrated fan/coil heat exchanger assembly connected in an annular form or shape in which hydronic solution circulates. An enhanced air conditioning chiller system according to present disclosure includes a system control module designed to manage the operation of the discreet loops utilizing temperature sensing devices, pressure sensing devices, motorized modulation valves, and unique programming techniques to optimize the efficiency of the enhanced air conditioning chiller system.
This invention, the enhanced air conditioning chiller system, is operated in two distinct and separate operating modes, including the charging cycle and the space conditioning cycle, each operating in an enhanced efficiency not otherwise obtainable without the patented stabilizer and the controls system necessary to manage it. With this invention, the enhanced air conditioning chiller charging cycle is operated by the activation of the refrigeration loop. The secondary circuit, the enhanced air conditioning chiller space conditioning cycle, is activated by the operation of the hydronic solution loop.
The enhanced air conditioning chiller primary cycle, herein referred to as the charging cycle, operated by the activation of the refrigeration loop includes a compressor upstream of a fan/coil condenser, stabilizer upstream of an electronic expansion valve, electronic expansion valve upstream of an evaporator, with evaporator upstream of the compressor. The refrigeration loop is enhanced with the patented liquid to liquid heat exchanger (“aka stabilizer”) downstream of the enhanced air conditioning chiller fan/coil condenser. The working medium in the form of a cold refrigerant is directed through the evaporator of the refrigeration loop to absorb heat from the warm hydronic solution within the hydronic solution loop to support the charging of the ice or freezing of brine or other solution contained within the static reservoir of the ice storage vessel. The enhanced air conditioning chiller refrigeration loop shares the hydronic solution that is operative in the evaporator in parallel with the stabilizer. The hydronic solution emanating from the stabilizer has the effect of burning off frozen medium at the static reservoir of the ice storage vessel, while the hydronic solution emanating from the evaporator has the effect of charging or freezing the energy storage medium within the static reservoir of the ice storage vessel. The enhanced air conditioning chiller delivers hydronic solution at a combined temperature from the evaporator and stabilizer approximately equal to or less than the freezing of water or other energy storage medium within the ice storage vessel static reservoir. Hydronic solution enters the stabilizer at the first intersection/split, interfacing with cooler hydronic fluid resulting in a cooling of the hot liquid refrigerant passing through the integrated heat exchanger. A motorized modulation valve is positioned upstream of the stabilizer to allow control of hydronic solution flow by modulating the valve from the closed to the open position effectively controlling the mass flow rate of the hydronic solution and in turn its temperature. Hydronic solution enters the enhanced air conditioning chiller evaporator at the second intersection/split, with motorized modulation valve being in the fully open position, allowing for mass flow rate control by the VFD controlled pump through the system control module. Precise hydronic solution mass flow rate is managed though the system control module providing direction to the hydronic VFD pump, positioned upstream of ice storage vessel. The parallel hydronic solution passages at the first and second intersections/splits, servicing the enhanced air conditioning chiller stabilizer and evaporator uniquely and simultaneously, are merged and blended and subsequently routed through the ice storage vessel. The enhanced air conditioning chiller stabilizer draws energy from the static reservoir, whereas the evaporator facilitates the formation of ice or freezing brine solution within the static reservoir contained within the ice storage vessel simultaneously. After passing through the upstream electronic expansion valve, refrigerant vapor enters the enhanced air conditioning chiller evaporator. The electric expansion valve adopts those principles found within a conventional air conditioning chiller, with pressure and sensible temperature sensors upstream of the evaporator, determining the mass flow rate of refrigerant through the evaporator based upon a superheat constant. Superheated cold refrigerant gas emitted from the evaporator is then routed to the compressor. Refrigerant pressure and temperature sensor devices upstream of the compressor provide signal to the systems control module whereby finite control of motorized modulation valve, upstream of stabilizer, is managed. The optimized pressure and temperature refrigerant gas as a result of the stabilizer then enters and exits fan/coil condenser, downstream of the compressor, whereby heat is expelled to the ambient environment resulting in a phase change of said gas refrigerant to a liquid state; a process conducted at constant pressure and temperature. Subsequently liquid refrigerant at sub-cooled temperature and constant pressure are monitored by temperature and pressure sensors respectively downstream of fan/coil condenser with their data transmitted to the enhanced air conditioning chiller system control module.
The enhanced air conditioning chiller secondary or space conditioning cycle activated through the operation of the hydronic solution loop incorporates an ice storage vessel, VFD Controlled Hydronic pump, a single or multiple pumps in an array, with space or zone air handler, or multiple air handlers in an array, provide cooling to the space or zone through their integrated fan/coil assembly within the air handler. The fan/ coil assembly of the air handler deposits heat from the warmer air from space or zone into the cooler hydronic solution. The hydronic solution is then routed in portions through the ice storage vessel, depositing heat into the static reservoir resulting in a melting of the ice or frozen brine or other solution. The hydronic solution loop includes a return leg and a bypass leg downstream of the air handler, prior to the ice storage vessel. The return and bypass legs are controlled by motorized modulation valves managed by the system control module. The system control module utilizes a temperature sensing device to control the bypass and return legs, allowing a portion of the warm hydronic solution from the air handler to return to the ice storage vessel, and the remaining portion to be bypassed to downstream of the ice storage vessel. Warm hydronic solution from the air handler is mixed with the cold hydronic solution emanating from the ice storage vessel to manage the ideal temperature required at the entrance of the air handler.
It is contemplated that the system of this invention can be operated when exterior temperatures are cool, such as overnight and in early morning hours, in a manner which emphasizes cooling of the hydronic solution at the evaporator of the refrigeration circuit, so that the hydronic solution is conducive to the formation of ice/energy storage within the ice storage vessel static reservoir. Ice building or alternately the freezing of brine or other solution is selectively performed during such cooler time periods.
In one aspect of this invention, the enhanced air conditioning chiller charging cycle operation is in part comprising: hydronic heat transfer solution, movably disposed in a closed discrete loop that includes a condenser (“aka stabilizer”), Variable Frequency Drive (VFD) pump, and a rechargeable heat absorbing component within an ice storage vessel connected through at least one conduit; wherein the stabilizer is operative to enable the transfer of heat between the hydronic solution and refrigerant exiting the fan/ coil condenser of the enhanced air conditioning chiller system; wherein the rechargeable heat absorbing hydronic solution is operative to absorb heat from the refrigerant passing through the stabilizer; wherein VFD controlled hydronic pump is operative to cycle the hydronic solution through the stabilizer and its refrigerant interface and the rechargeable heat absorbing ice storage vessel, thereby enabling heat from the refrigerant to be absorbed into the hydronic solution and subsequently transferred to the ice storage vessel static reservoir.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation includes a hydronic solution motorized modulation valve located at the stabilizer outlet that is managed by the system control module utilizing readings from the inlet and outlet refrigerant pressure and temperature sensors. The pressure and temperatures are monitored and viewable through the system control module.
In another aspect of this invention, the enhanced air conditioning chiller charging loop operation features the refrigerant pressure associated with the fan/coil condenser, equal to the stabilizer, allowing for the hydronic solution motorized modulation valve to appropriately open and close to maintain an optimum flow rate, thereby allowing for the hydronic solution to exit the stabilizer at an elevated temperature and the liquid refrigerant to exit at a much-reduced temperature.
In another aspect of this invention, the enhanced air conditioning chiller charging loop operation features the refrigerant pressure sensor measuring the constant pressure maintained throughout the enhanced air conditioning chiller charging loop compressor operation with an accompanying temperature sensor providing refrigerant sensible superheated temperature utilized in the operation of the stabilizer through an enhanced air conditioning chiller system control module.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the refrigerant pressure sensor utilized in determination of the refrigerant superheated saturation temperature made possible through the refrigerant properties table residing within the system control module; wherein the refrigerant sensible superheated temperature and vapor saturation temperature are compared to one another for equality, with refrigerant glide/drift considered, and then subsequently checked ensuring they exceed ambient temperature with its operation administered through the enhanced air conditioning chiller system control module.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the hydronic solution motorized modulation valve, operating between open and closed positions to satisfy specified operating criteria; the positioning of the hydronic solution modulation valve is administered by the air conditioning chiller system control module.
In another aspect of this invention, the air conditioning chiller charging cycle operation features hydronic solution passing through the stabilizer, absorbing heat energy from the liquid refrigerant, emanating from the enhanced air conditioning chiller fan/coil condenser, managed through the system control module; wherein the stabilizer hydronic solution liquid refrigerant interface is defined as a heat exchanger working ideally on a liquid to liquid sensible temperature basis as opposed to a latent phase change basis.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features a VFD-operated pump operative to cycle the hydronic solution through the stabilizer refrigerant interface and subsequently the rechargeable heat absorbing ice storage vessel static reservoir, thereby transferring heat from the refrigerant into the hydronic solution, where the heat is then transferred to the ice storage vessel ice or frozen brine solution, or other solution type static reservoir interfaced with the hydronic solution contained within a closed configuration of a network of piping/conduit.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the ice storage vessel static reservoir absorbing heat energy from the hydronic solution emanating from the enhanced air conditioning chiller stabilizer.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the hydronic solution supporting a phase change of the rechargeable heat absorbing ice storage vessel static reservoir.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the VFD-operated hydronic pump mass flow rate as a function of the stabilizer modulation valve positioning in conjunction with the dynamically changing load source of the evaporator drawing from the ice storage vessel static reservoir and is administered through the system control module; wherein the stabilizer draws upon the energy capacity of the ice storage vessel static reservoir resulting in the continuous melting of the residual ice or other partially solidified brine or other type solution.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the liquid refrigerant at reduced temperature and constant pressure exiting the stabilizer and undergoing expansion through the electronic expansion valve resulting in the partial vaporization of refrigerant, having a composition of gas and liquid, defined as a vapor, exiting the expansion valve at low pressure and temperature.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation, in part comprises: a heat transfer medium, hydronic solution, movably disposed in a closed, discrete loop that includes the evaporator, Variable Frequency Drive (VFD) pump, and a rechargeable ice storage vessel, connected through at least one conduit; wherein the evaporator is operative to enable the transfer of heat between the hydronic solution and vapor refrigerant, emanating from electronic expansion valve, exiting as a refrigerant gas having undergone a latent thermodynamic process under constant pressure; the refrigerant temperature adjusted by the electronic expansion valve through its control panel by way of a programmable superheat value; wherein the expansion valve control panel allows for real time changes to select variables, including the superheat value, associated with the enhanced air conditioning chiller charging cycle operation made possible through the system control module; herein the select operating variable changes to the programmable expansion valve control panel are accommodated through a communication protocol, including but not limited to RS485 or RS232; wherein select values contained within the electronic expansion valve control panel are monitored and viewable by the system control module.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the hydronic solution motorized modulation valve at the exit of the evaporator remaining actively open, allowing for the continuous flow of said hydronic solution.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features hydronic solution discharging heat energy to the refrigerant vapor within the evaporator supporting the refrigerant phase change from vapor to gas, resulting in a hydronic solution temperature exiting the evaporator at a conducive temperature to allow for solidification or freezing of the static rechargeable heat absorbing medium within the ice storage vessel, such as water, brine, or other solution type medium; wherein the hydronic solution conduit contains a temperature sensing device at the exit of the evaporator to measure its temperature.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the ice storage vessel static reservoir containing an electronic detection device measuring the percentage of solidification/freezing of static rechargeable medium contained within its static reservoir.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the ice storage vessel static reservoir interfacing with the hydronic solution contained within a closed network of conduit/piping. The hydronic solution exits the ice storage vessel having absorbed heat energy from the rechargeable medium within the static reservoir; a temperature sensing device is located within the hydronic solution closed network at the exit of the ice storage vessel to measure its temperature upon departure of said vessel; wherein the temperature of the hydronic solution exiting the ice storage vessel is compared with a set point temperature utilized in the completion of the freezing/solidification process of the rechargeable medium within the static reservoir of the ice storage vessel; wherein a detection device measuring the percentage of freezing/solidification of the rechargeable medium within the static reservoir of the ice storage vessel utilized as a redundant feature along with the aforementioned temperature sensing device providing confirmation of the completion of freezing/solidification of the rechargeable medium within the static reservoir; wherein the solidification/frozen detection device provides for a secondary means of confirmation of process completion of the rechargeable medium contained within the static reservoir.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features refrigerant that is discharged from the evaporator as gas composition and contains a temperature and pressure sensor measuring its sensible temperature and pressure respectively; whereby said temperature and pressure sensors are utilized in protection of the compressor, allowing for termination of its operation when compared to manufacture threshold pressure and temperature set points.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation is in part comprised of various refrigeration and hydronic components, wherein the low temperature and pressure refrigerant gas discharged from the evaporator undergoes compression as it is passed through the enhanced air conditioning charging/ refrigeration compressor, where it exits as a high pressure and temperature gas; wherein the electrical power usage associated with the air conditioning chiller compressor is recorded by an energy monitoring device.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the temperature of the hydronic solution at the evaporator inlet and outlet being utilized in conjunction with the compressor’s power to provide finite control of the hydronic solution flow; wherein the hydronic solution flow rate is made possible through the modulating VFD pump thereby maximizing the efficiency of the evaporator.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the stabilizer providing a low temperature liquid refrigerant to the expansion valve, where it undergoes rapid expansion, yielding a low pressure and temperature vapor composition refrigerant, thereby allowing for enhanced operation of the evaporator; wherein the stabilizer delivers optimized liquid refrigerant temperature at constant pressure to the electronic expansion valve and subsequently the evaporator, providing low pressure and temperature gas to the compressor, where it exits at an optimized high pressure and temperature; wherein the collective enhanced performances of the evaporator and the fan/coil condenser, as a consequence of the stabilizer, provides for an overall optimization in the efficiency of the enhanced air conditioning chiller refrigeration/charging loop operation; wherein the increase in enthalpy across the condensing circuit, fan/coil condenser and stabilizer, demonstrates analytically the greater ability to expel heat energy, providing evidence of its enhanced operating performance; wherein it can be analytically demonstrated that the evaporator ability to absorb greater heat energy is reflected by the increase in absolute enthalpy which provides evidence to its enhanced performance.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the ice storage vessel static reservoir functioning as a heat sink in the stabilizer operation; wherein the ice storage vessel static reservoir functions as a load source in the operation of the evaporator; wherein the ice storage vessel static reservoir is designed for the simultaneous operations of the stabilizer and evaporator providing an aggregate efficiency increase to the enhanced air conditioning chiller charging cycle operation.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features an integral real time clock within the system control module which governs that period in which the enhanced air conditioning charging cycle operation is active; wherein the integral real time clock within the system control module closes hydronic solution motorized modulation valves associated with the enhanced air conditioning chiller space air conditioning loop to preclude its operations.
In another aspect of this invention, the enhanced air conditioning chiller space air conditioning loop operation is comprised of: a heat transfer medium, hydronic solution, movably disposed in a closed, discrete space air conditioning loop that includes an air handler or multiple air handlers assigned to one or more spaces/zones, a Variable Frequency Drive (VFD) hydronic pump, and a rechargeable ice storage vessel, connected through at least one conduit; wherein the air handler(s) are operative to enable the transfer of heat energy between the hydronic solution and air contained within the spaces/ zones by method of the air being drawn through their coil by a fan or blower; wherein the spaces/zones temperature are controlled by a controller directly associated with the air handler operations; wherein the hydronic solution flow associated with the air handler(s) is managed through an on/off type valve with accompanying circuit setter, pressure limiting type device, at its discharge; wherein the fan or blower associated with the air handler(s) is activated by the space/zones’ controller integrated with the system control module.
In another aspect of this invention, the enhanced air conditioning chiller space conditioning cycle operation features a system control module managing the hydronic solution distribution flow rate achieved by the VFD operated pump; wherein the hydronic solution distribution network of piping/conduit is fitted with a pressure sensing device that is correlated to flow rate data unique to the pump through the system control module, thereby facilitating the demands of the spaces/zones air handler(s).
In another aspect of this invention, the enhanced air conditioning chiller space conditioning cycle operation features the temperature of the blended hydronic solution legs measured by a temperature sensor upstream from motorized modulation valves providing for an optimum temperature necessary to maintaining precise space/zones temperature control.
In another aspect of this invention, the enhanced air conditioning chiller space conditioning cycle operation features the enhanced air conditioning charging cycle operation terminated with the closure of hydronic solution modulation valves associated with the stabilizer and the evaporator.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle and space conditioning cycle operations features the ice storage vessel and VFD controlled hydronic pump utilized by the enhanced air conditioning charging cycle and space conditioning cycle operations; wherein the air conditioning chiller charging cycle and space conditioning cycle are activated independent of one another at different time periods.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle and space conditioning cycle operations feature the enhanced conditioning chiller charging cycle operation of the ice storage vessel and VFD pump uniquely utilized through the system control module.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle and space conditioning cycle operations feature hydronic diversity existing between the independent operations of the air conditioning charging cycle and the space conditioning cycle operations dictate the utilization of independent VFD-controlled hydronic pumps in each of their respective loops.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle operation features the VFD controlled hydronic pump operationally conforming to the hydronic tasking required of the enhanced air conditioning charging cycle operation; wherein the VFD controlled hydronic pump associated with the space conditioning hydronic loop operation remains deactivated.
In another aspect of this invention, the enhanced air conditioning chiller space conditioning cycle operation features the VFD controlled hydronic pump operationally conforming to the hydronic tasking of the space conditioning cycle operation; wherein the VFD controlled hydronic pump associated with the enhanced air conditioning charging cycle operation remains deactivated.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module facilitates the operation of various aspects of this invention, the integrated real time clock within the system control module dictates the time of operation, determined by end user, of the enhanced air conditioning chiller charging cycle; wherein the hydronic solution modulation valves close, precluding their flows emanating from the ice storage vessel and air handler(s), thereby terminating the space conditioning cycle operation.
In another aspect of this invention, the enhanced air conditioning chiller space conditioning cycle system control module facilitates the operation of various aspects of this invention; wherein the integrated real time clock within the system control module dictates that time of operation, determined by end user, of the air conditioning chiller space conditioning cycle operation; wherein the hydronic solution modulation valves close, precluding flows emanating from the evaporator and stabilizer, thereby terminating the enhanced air conditioning chiller charging cycle operation.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operates according to various aspects pertaining to the stabilizer, features the hydronic solution modulation valve at the exit to stabilizer provided with operational direction through the system control module resulting from the pressure sensing device and its associated temperature sensor measuring sensible superheat temperature inputs; where said pressure allows access to refrigerant properties tables residing within the system control module memory, containing the refrigerant saturation temperature; wherein the saturation temperature of the refrigerant is compared to the superheat temperature of the refrigerant by the control systems module, ensuring that they are equal. When the saturation and sensible temperature are equal to 15 degrees above the ambient temperature, we achieve ideal conditions for complete condensing of the refrigerant through the latent phase change process. When the saturation and sensible temperatures are greater than 15 degrees above the ambient temperature, the motorized modulation valve is opened to a greater position and conversely when less than the aforementioned temperature the motorized modulation valve is closed toward a lesser position; the motorized modulation valve is a unique feature of the enhanced air conditioning charging cycle operation, managed by the system control module; wherein the stabilizer provides the optimized refrigerant liquid temperature ensuring the completion of the air conditioning chiller fan/coil condenser operation; wherein the temperature and pressure at fan/coil condenser’s entry are conducive to the aforementioned threshold temperature, monitored through the system control module, thus effectively eliminating the sensible heat transfer of the superheat region of the refrigerant properties resulting in energy conservation.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operation of the above aspects are pertinent to the evaporator, wherein the hydronic solution temperature sensing devices associated with the evaporator provide temperature inputs to the system control module at its entry and exit; wherein the enhanced air conditioning chiller compressor contains a power monitoring device providing readable outputs to the system control module; wherein a mathematical computation is made possible through the system control module processor, utilizing the evaporator’s input and output hydronic solution temperatures along with the power attributed to the enhanced air conditioning chiller system compressor, which allows for the determination of ideal hydronic solution flow rate and yielding maximum efficiency of the evaporator.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operates according to various aspect features of the collective optimization of the air conditioning chiller system evaporator and stabilizer to providing evidence to the enhanced air conditioning chiller charging cycle overall efficiency.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operation features the refrigerant temperature sensing devices and pressure sensing devices, at the evaporator refrigerant discharge, providing temperature and pressure outputs read by the system control module; wherein the refrigerant discharge pressure exiting the evaporator allows for accessibility to property tables, residing within the system control module memory, to obtain the refrigerant liquid saturation temperature; wherein the temperature sensor at the refrigerant discharge of the evaporator provides for its sensible liquid temperature; wherein a mathematic computation executed by the system control module processor provides the absolute difference between saturated liquid and sensible liquid temperature, referred to as sub-cool, critical to the enhanced air conditioning chiller charging cycle operation.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operation features the temperature and pressure sensing devices, at the evaporator refrigerant discharge, providing temperature and pressure outputs read by the system control module; wherein an analytical comparison is made between actual refrigerant pressure and temperature exiting the evaporator against threshold temperature and pressure, residing with the system control module, whereby termination of the air conditioning charging cycle operation can occur in the event threshold temperature and pressure are exceeded.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operation features hydronic solution temperature sensing devices at entry to and exit from the ice storage vessel to provide temperature data outputs read by the system control module, retained within local memory as well as stored in a remote location for both local and remote display and future access and assessments; wherein that temperature sensing device associated with hydronic solution exiting the ice vessel is compared to a temperature threshold value stored within system control module; wherein said temperature of hydronic solution is greater than the threshold temperature, the enhanced air conditioning chiller charging cycle continues operation; in the event the temperature drops lower than the threshold temperature, the air conditioning chiller system charging cycle ceases operation; wherein the device provides a secondary means by which to confirm the solidification/freezing of the static reservoir within the ice storage vessel; confirmation is made possible by equating the secondary control reading to the temperature sensing device at the discharge from ice storage vessel evaluated through the system control module.
In another aspect of this invention, the enhanced air conditioning chiller space conditioning cycle system control module operation features operating conditions which are prevalent; wherein the temperature sensing device associated with return hydronic solution flow, a percentage of the total, emitted to the ice storage vessel, is a measure of the temperature associated with heat gain from the space air handler; wherein the rate of hydronic solution flow exiting the ice storage vessel is restricted by a motorized modulation valve, where its flow is merged with the air handler bypass motorized modulation valve flow, providing full required flow to the air handler; wherein the motorized modulation valves are positioned proportional to one another as a function of the temperature sensing device measuring the blended hydronic solution flows; wherein a temperature threshold, residing within the system control module memory is compared with blended temperature for equality and maintained about such; wherein the blended temperature of the hydronic solution allows for temperature maximizing the performance of air handler allowing for precise space temperature management.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operation features the modulation valve opening and closing under a single hydronic solution pump application providing finite control of the stabilizer of the air conditioning charging cycle operation.
In another aspect of this invention, the enhanced air conditioning chiller charging cycle system control module operation features a modulation valve which opens and closes under a single hydronic solution pump application, providing finite control of the evaporator of the air conditioning charging cycle operation.
In another aspect of this invention, the enhanced air conditioning chiller space conditioning and charging cycle system control module operation under a single hydronic solution pump type application provides finite control of its flow, utilizing the pressure sensor of the space conditioning cycle hydronic solution.
A primary objective of the present invention is to provide an enhanced air conditioning chiller which can maintain high performance operation even in suboptimal environmental conditions.
Another objective of the present invention is to provide an enhanced air conditioning chiller which is configured to keep a refrigeration loop of the system operating within optimized design parameters in a variety of different surrounding environmental conditions.
Another objective of the present invention is to provide an enhanced air conditioning chiller which can store excess capacity to absorb heat from air or otherwise, which excess capacity can then be utilized in periods of high demand to maintain desired performance levels in challenging environmental conditions.
Another objective of the present invention is to provide an enhanced air conditioning chiller which has multiple heat transfer interconnections between a chiller circuit and a refrigeration circuit, including both heat transfer into the refrigeration circuit and heat transfer out of the refrigeration circuit, relative to the chiller circuit, to keep the refrigeration circuit operating optimally.
Another objective of the present invention is provide a method for cooling air within a space/zones which has high reliability and high efficiency, while providing high performance.
Another objective of the present invention is to provide an enhanced air conditioning chiller which includes automated controls to route chiller fluid along various different pathways of a chiller circuit, to optimize performance of the overall enhanced air conditioning chiller.
Another objective of the present invention is to replace and/or displace the use of water source condensers that result in the waste of conditioned potable water resources with that of an air source condenser system to optimize the performance and reduce first time costs associated with the installation of a chiller type system. The displacement of water source condensers is particularly necessary in locations with high humidity constraints.
Another objective of the present invention is to provide an enhanced air conditioning chiller to provide substantial improvements to the system efficiency, to include but not limited to the EER and the COP calculations of the traditional air conditioning chiller system as a result of the inclusion of the specialized system control module and its associated software and the stabilizer.
Other further objectives of the present invention will become apparent from a careful reading of the included drawing figures, the claims and detailed description of the invention.
The operation of the conventional air conditioning chiller 10 is defined by two independently operated cycles, the charging cycle and the space conditioning cycle. The refrigeration loop operation during the charging cycle is defined by the operation of the refrigeration equipment including compressor 11, fan/coil condenser 12, expansion valve 13, and the integration of evaporator 41. The space conditioning cycle is defined by operation of air handler 14. Hydronic solution pump 22 is operative during both cycles, and the ice storage vessel 21 is utilized during both cycles. Ice storage vessel 21 is utilized during the charging cycle as the load source to the evaporator 41, and as a load sink during the space conditioning cycle to air handler 14. Traditionally the operation of the two independent cycles are controlled by a time clock contained within the system control module.
During the charging cycle, the conventional air conditioning chiller system 10 is tasked with charging the ice storage vessel 21. The refrigerant compressor 11, downstream of evaporator 41, provides the work necessary to support the charging cycle by doing work on the cold refrigerant gas emitted from evaporator 41 through piping element 04 and producing a superheated gas at high pressure to fan/coil condenser 12 through piping segment 01. At fan/coil condenser 12, the refrigerant is interfaced with the ambient air through the use of a fan and an integrated heat exchanger, reducing the temperature of the refrigerant while the pressure remains constant, a sensible temperature change. As the temperature is reduced to the demarcation point, the refrigerant enters a latent phase change process where temperature and pressure are held constant, while the refrigerant transitions from a very hot gas to a hot liquid refrigerant. Upon completion of the latent phase change of the refrigerant, the refrigerant may undergo additional sensible temperature reduction prior to exiting the fan/coil condenser 12. The refrigerant exits fan/ coil condenser 12 through piping segment 02 as liquid refrigerant having undergone a complete phase change under optimal or ideal conditions. This phase change is made possible by drawing cooler ambient air across the fan/coil condenser 12, causing the air to absorb heat energy from the refrigerant received from compressor 11, resulting in a cooled gaseous liquid, or vapor, refrigerant exiting fan/coil condenser 12, or ideally a complete liquid. In order to complete this phase change within the fan/coil condenser 12, it is well established in the refrigeration industry that the refrigerant must enter the fan/ coil condenser at a minimum of 15 degrees above the ambient temperature for single pass condenser coils and 30 degrees for double pass condenser coils. Expansion valve 13 can be either mechanical or electronic, and is located downstream of fan/coil condenser 12 between piping segments 02 and 03. Under optimal conditions, expansion valve 13 receives a hot liquid refrigerant at a high pressure from fan/coil condenser 12 through piping segment 02, at a temperature no less than the ambient temperature due to the second law of thermodynamics, and discharges to the evaporator 41 through piping segment 03 as a low temperature vaporous refrigerant at a low pressure. Evaporator 41, downstream of expansion valve 13, is shared mutually by both the refrigeration and hydronic solution loops through its integrated heat exchanger. Evaporator 41 is tasked with the partial phase change of refrigerant, received from expansion valve 13, from a vapor to a complete superheated gas at a low temperature and pressure. The evaporator receives the required relatively warm hydronic solution from the ice storage vessel 21 as a result of the hydronic solution picking up heat energy from the ice storage vessel 21 static reservoir through its integrated heat exchanger. The integrated heat exchanger within evaporator 41 allows heat energy to be transferred from the warm hydronic solution to the very cold refrigerant received from expansion valve 13, resulting in the hydronic solution exiting the evaporator 41 in a much colder state, conducive to the freezing of the static reservoir of the ice storage vessel 21, and the refrigerant exiting the evaporator 41 in a much warmer, fully gas state. The cooled hydronic solution is then directed through piping segments 10 and 06 to the integrated heat exchanger of the ice storage vessel 21 where heat from the static reservoir is absorbed by the hydronic solution continuously until the static reservoir is in a frozen state. The hydronic fluid is continuously circulated through piping segments 06 through 10 by the hydronic pump 22 during the operation of the charging cycle. The charging cycle continues until the completed freezing of the static reservoir of the ice storage vessel 21.
During the space conditioning cycle the conventional air conditioning chiller system 10 is tasked with maintaining the space or zone temperature associated with air handler 14. The load source of the space conditioning cycle is the air handler 14, which may be a single air handler or a series or array of air handlers. The space conditioning cycle maintains the space or zone temperature by drawing warm air from the conditioned space or zone across its fan/coil assembly that interfaces the conditioned space or zone air with the cold hydronic solution received from ice storage vessel 21 through pipe element 07, depositing the heat from the space or zone to the hydronic solution. The hydronic solution is circulated by a hydronic pump 22, or multiple pumps, upstream of air handler 14, that is managed through a variable frequency drive, hereafter referred to as a VFD. Modulation of the drive frequency or speed is determined by the heat load demands emanating from space or zone thermostat, or other similar temperature sensing device, activating the air handler 14 fan operation. By the operation of pump 22, the elevated temperature hydronic solution exiting air handler 14, through pipe elements 05 and 06, deposits heat energy from the space or zone to the static reservoir of the ice storage vessel 21 through its integrated heat exchanger. The motorized modulation valve 52 allows a metered amount of hot or warmed hydronic solution emitted from the air handler 14 to be bypassed from the ice storage vessel 21 and deposited downstream of the ice storage vessel 21, mixing with the hydronic solution within piping segment 07, prior to entering air handler 14 to ensure the supply temperature to the air handler matches manufacturer and design specifications. Motorized modulation valve 52 is modulated to allow more or less hydronic solution to bypass ice storage vessel 21 based upon the conventional air conditioning chiller control system monitoring the supply temperature within piping segment 07 by way of a temperature sensing device. The motorized modulation valve 62 operates in opposing manner to motorized modulation valve 52, allowing the remainder of the warm or hot hydronic solution emanating from the air handler 14 to return to the ice storage vessel 21, where the solution can be cooled and heat deposited to the static reservoir heat exchanger component, prior to exiting through piping segment 07. The space conditioning cycle is only operative when the thermostat or other temperature measuring devices indicates the requirement of cooling the space or zone.
The hydronic solution loop of
Temperature sensing device and pressure sensing device 207 located on piping segment 01 of
The system control module monitors the hydronic solution emanating from the ice storage vessel 121 by temperature sensing device 220. Relatively low temperature glycol solution emanating from the ice storage vessel 121 is utilized by the stabilizer 131 to artificially reduce the temperature of the refrigerant that exits the fan/coil condenser 112. The temperature of the glycol solution exiting stabilizer 131 is monitored by temperature sensing device 215.
The system control module calculates both the superheat saturation temperature and sub-cool saturation temperatures using the integrated refrigeration properties tables. The system control module is able to identify points of demarcation associated with the transition of gas refrigerant to a complete liquid state, allowing it to determine the upper and lower values for enthalpy (H), or a thermodynamic quantity equivalent to the total heat content of a system. The absolute difference between the upper and lower enthalpy values reflects the amount of heat energy (Q) rejected to the ambient air by the fan/coil condenser 112. The system control module determines the sub-cool saturation temperature and the physical temperature of liquid refrigerant exiting stabilizer 131, allowing it to be able to obtain the upper and lower enthalpy values from the refrigerant properties tables contained within the system control module. The absolute difference between the upper and lower enthalpy values indicates the amount of additional heat energy (Q) removal by patented stabilizer 131.
The system control module maintains modulation valve 142 in the open position in order to maximize the volume of hydronic solution received by evaporator 141 during the charging cycle. Flow measuring device 300 is monitored by the system control module in order to validate the proper flow required by evaporator 141. The system control module manages the variable frequency drive that operates hydronic pump 122 to a flow rate value as deemed appropriate through the system control module programming to optimize the performance of evaporator 141 and ice storage vessel 121. Temperature measuring device 215 and 220 are monitored by the system control module to confirm the hydronic solution temperatures entering and exiting ice storage vessel 121, ensuring the proper operation of the heat exchanger elements within the ice storage vessel 121 and evaporator 141. Temperature sensing device and pressure sensing devices 200 is monitored directly by the electronic expansion valve 113 integrated control panel, which is read by the system control module. Temperature sensing device and pressure sensing device 210 is monitored by the system control module to ensure that the temperature of refrigerant entering evaporator 141 is in a sub freezing temperature state in order to provide the required heat exchange with the warm hydronic solution received from ice storage vessel 121 and subsequently to provide sub freezing temperature hydronic solution to the static reservoir of the ice storage vessel 121. The compressor 111 is equipped with a power monitoring device, with an output value of power to the system control module. With the power consumption of the compressor 111 determined, the system control module is able to compare the power consumption of the compressor 111 and that of the evaporator 141, adjusting various instrumentation and controls in order to minimize the power differential between them allowing the charging cycle of the enhanced air conditioning chiller system 100 or 110 to operate at maximum efficiency. The power monitoring device of compressor 111 additionally allows the system control module to calculate system performance, commonly referred to as EER, or Energy Efficiency Ratio.
Temperature sensing device and pressure sensing device 200 are monitored by the system control module for temperature and pressure respectively. The system control module obtains the pressure reading from pressure sensing device 200 and calculates the enthalpy, or energy available, and refrigerant superheat saturation temperature based upon internal refrigerant properties tables. The refrigerant superheat saturation temperature calculated signifies the transition point of the cold vapor refrigerant to its complete gas state. The refrigerant transition process completion is identified by the system control module when the reading from the temperature sensing device 200 is between 1 and 5 degrees above the calculated refrigerant superheated temperature value.
The hydronic solution emanating from the ice storage vessel 121, upstream of stabilizer 141, is monitored by temperature sensing device 220 by the system control module. The temperature of the hydronic solution exiting stabilizer 141 integrated heat exchanger is monitored by temperature sensing device 215 to ensure sub-freezing temperature hydronic solution required to charge the static reservoir of the ice storage vessel 121.
Motorized modulation valve 142 is maintained at a 100% open position through the system control module during the entirety of the charging cycle. Hydronic pump 122, downstream of motorized modulation valve 142, is controlled by a variable frequency drive (VFD). The VFD is controlled by the system control module to maintain and set the hydronic solution flow rate required by evaporator 141. The system control module determines the appropriate flow rate through a mathematical formula, with validation of flow rate by reading flow monitoring device 300 at a regular interval.
Consideration is made by the system control module to accommodate the effect of the flow rate of hydronic solution by stabilizer 131. Upon the opening or closing of the motorized modulation valve 132, the system control module reads flow monitoring device 300 on a regular interval to ensure proper glycol solution flow rate to evaporator 141. Additionally, as the system control module makes adjustments to the VFD controlling hydronic pump 122, consideration is given to a potential delay in response from flow monitoring device 300, and allows a pre-determined timed delay between adjustments being made to the VFD through the system control module.
The hydronic solution loop of
This disclosure is provided to reveal a preferred embodiment of the invention and a best mode for practicing the invention. Having thus described the invention in this way, it should be apparent that various different modifications can be made to the preferred embodiment without departing from the scope and spirit of this invention disclosure. When embodiments are referred to as “exemplary” or “preferred” this term is meant to indicate one example of the invention, and does not exclude other possible embodiments. When structures are identified as a means to perform a function, the identification is intended to include all structures which can perform the function specified. When structures of this invention are identified as being coupled together, such language should be interpreted broadly to include the structures being coupled directly together or coupled together through intervening structures. Such coupling could be permanent or temporary and either in a rigid fashion or in a fashion which allows pivoting, sliding or other relative motion while still providing some form of attachment, unless specifically restricted. When a structure is “upstream” of another structure, this includes both directly upstream with no intervening equipment and indirectly upstream with intervening equipment. When a structure is “downstream” of another structure, this includes both directly downstream and indirectly downstream
For ease of reference, the following glossary is provided relating to terms and concepts discussed above.
Latent Thermodynamic Process: Defined as a constant pressure/temperature process from the saturated liquid line to the saturated vapor line, whereby a thermal dynamic process of changing a substance phase, Pressure-Enthalpy diagram.
Enthalpy: A quantity associated with a thermodynamic system, expressed as the internal energy of a system plus the product of the pressure and volume of the system, having the property that during an isobaric process, the change in the quantity is equal to the heat transferred during the process.
Isobaric: Having or showing equal barometric pressure.
Isothermal: Occurring at constant temperature.
Isotropic: Of equal physical properties along all axes.
Entropy:
Sensible Thermodynamic Process: Heat exchanged by a body or thermodynamic system that changes the temperature, and some macroscopic variables of the body, but leaves unchanged certain other macroscopic variables, such as volume or pressure.
Subcool: The measure of the temperature difference between saturated vapor (or liquid) and vapor, at constant pressure, as it applies to the condensing coil of an air conditioning unit.
Superheat: The measure of the temperature difference between saturated vapor (or liquid) and vapor, at a constant pressure, as it applies to the evaporative coil of an air conditioning unit.
2nd Law of Thermodynamics: States that the entropy of an isolated system never decreases, because isolated systems always evolve toward thermodynamic equilibrium, a state with maximum entropy; heat always transfers higher temperature medium to a lower temperature medium.
VFD: A type of motor controller that drives an electric motor by varying the frequency and voltage supplied to the electric motor. Other names for a VFD are variable speed drive, adjustable speed drive, adjustable frequency drive, AC drive, microdrive, and inverter.
Hydronic: Denoting a cooling or heating system in which heat is transported using circulating water.
EER: The Energy Efficiency Ratio of an HVAC cooling device is the ratio of output cooling energy (in BTU) to input electrical energy (in watts) at a given operating point.
COP: Coefficient of Power defined as the relationship between the power (kW) that is drawn out of the heat pump as cooling or heat, and the power (kW) that is supplied to the compressor.
This application is a continuation-in-part of U.S. Pat. Application No. 17/189,538, filed on Mar. 2, 2021, incorporated herein by reference in its entirety. This application claims benefit under Title 35, United States Code §119(e) of U.S. Provisional Application No. 62/984,089 filed on Mar. 2, 2020.
| Number | Date | Country | |
|---|---|---|---|
| 62984089 | Mar 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17189538 | Mar 2021 | US |
| Child | 17988370 | US |
