This disclosure relates generally to manufacturing a process chiller. More specifically, this disclosure relates to a modular housing system for a process chiller and a method of manufacturing a modular process chiller configurable for use in one of various processing systems.
Process chillers are used for supplying cool fluids to various machines in manufacturing, food handling and other processing systems in which temperature control is necessary. Each processing system has unique challenges and different machines and processes require a reliable source of cool fluids. In general, a process chiller receives fluids that were heated by a machine in the processing system. The process chiller cools the fluid to an acceptable level and supplies cool fluids to the machine at a selected temperature, flow rate and fluid pressure. For example, a processing system in an industrial environment may involve a CNC machine that uses fluids to cool the workpiece and tooling, and a process chiller supplies cool fluids to the CNC and receives heated return fluids from the CNC machine. As the CNC machine operates, heat generated during the process can vary, but the process chiller ensures fluids used by the CNC machine are supplied with a temperature below a selected threshold. Similarly, a processing system in a food industry environment may require air temperature in a food handling container stay below a threshold temperature to ensure food stays fresh. A process chiller supplies fluids to allow an air conditioner in the food handling container to maintain air temperature below the threshold temperature.
Embodiments of a modular housing process chiller disclosed herein can be manufactured using standardized locations for selected components but allow other components to be positioned in combinations as needed to provide customized solutions for many different customer applications. In all configurations, the components are in the cold air stream to maximize efficiency and the condenser is always positioned such that a fan pulls (rather than pushes) air through the condenser.
Embodiments disclosed herein are directed to a method of manufacturing a process chiller with four sides selectively configurable for controlling air flow through the process chiller. The method comprises positioning a pump relative to a tank in a fluid module; positioning a fan in a refrigeration module relative to a condenser and a heat exchanger, wherein the condenser extends diagonally across the refrigeration module and divides the refrigeration module into two regions, wherein each region comprises two sides, wherein the heat exchanger is located in a first region and the fan is positioned on a first side in a second region opposite the heat exchanger; positioning an air permeable panel on at least one of a first side or a second side of the two sides in the first region, wherein air flows into the refrigeration module via the air permeable panel; positioning a nonpermeable panel on a second side in the second region, wherein the nonpermeable panel prevents air flow through the second side in the second region, wherein air flow passes from the first region through the condenser to the fan; coupling the refrigeration module to the fluid module; and coupling an electronics module to the refrigeration module in one of three configurations based on user access to the electronics module. The pump is positioned to a left side of the tank, a back side of the tank, or to a right side of the tank, wherein the fluid module comprises fluid connections configured to extend from a left side of the fluid module, a back side of the fluid module, or a right side of the fluid module for coupling to fluid conduits from one or more external sources. In some embodiments, positioning an air permeable panel on both the first side and the second side of the two sides in the first region allows air flow through both air permeable panels; positioning an air permeable panel on the first side of the two sides in the first region and positioning a nonpermeable panel on the second side of the two sides in the first region allows air flow through only the air permeable panel on the first side; and positioning an air permeable panel on the second side of the two sides in the first region and positioning a nonpermeable panel on the first side of the two sides in the first region allows air flow through only the air permeable panel on the second side. In various embodiments, the method comprises forming the tank with a front wall and at least one side wall, wherein at least one side wall is configured for user access to fluid connections in any one of the three configurations. In some embodiments, the tank comprises the front wall and two side walls, wherein each side wall is angled for access to the fluid connections. In some embodiments, the tank comprises at least a front wall and at least one curved wall, wherein the curved wall comprises a curvature for access to the fluid connections. In some embodiments, the process chiller is manufactured for positioning proximate an enclosure for a machine, wherein the enclosure comprises the nonpermeable panel.
Embodiments disclosed herein are directed to a process chiller with four sides selectively configurable for controlling air flow through the process chiller. The process chiller comprises a fluid module comprising a pump and a tank positioned relative to the pump in one of three configurations for coupling fluid connections to fluid conduits from one or more external sources. In some embodiments, the tank comprises a front wall and at least one side wall, wherein the at least one side wall is configured for user access to fluid connections in any one of the three configurations. In some embodiments, the tank comprises the front wall and two side walls, wherein each side wall is angled for access to the fluid connections. In some embodiments, the tank comprises at least a front wall and at least one curved wall, wherein the curved wall comprises a curvature for access to the fluid connections. The process chiller further comprises a refrigeration module comprising a condenser, a heat exchanger, a compressor and a fan. The condenser extends diagonally across the refrigeration module and divides the refrigeration module into two regions, wherein each region comprises two sides. The heat exchanger is located in a first region and the fan is positioned on a first side in the second region opposite the heat exchanger. The refrigeration module further comprises a plurality of panels, with an air permeable panel positioned on at least one of a first side or a second side of the two sides in the first region and a nonpermeable panel positioned on a second side in the second region. Air flow passes through the refrigeration module via the air permeable panel, wherein the nonpermeable panel prevents air flow through the second side, whereby air flow passes from the first region through the condenser to the fan. In some embodiments, positioning an air permeable panel on both the first side and the second side of the two sides in the first region allows air flow through both air permeable panels, positioning an air permeable panel on the first side of the two sides in the first region and positioning a nonpermeable panel on the second side of the two sides in the first region allows air flow through only the air permeable panel on the first side, and positioning an air permeable panel on the second side of the two sides in the first region and positioning a nonpermeable panel on the first side of the two sides in the first region allows air flow through only the air permeable panel on the second side. The process chiller further comprises an electronics module coupled to the refrigeration module in a configuration based on user access to the process chiller. In some embodiments, the process chiller is manufactured for positioning proximate an enclosure for a machine, wherein the enclosure comprises the nonpermeable panel.
Embodiments disclosed herein are directed to a processing system, comprising a process chiller with four sides selectively configurable for controlling air flow through the process chiller. The process chiller comprises a fluid module comprising a pump and a tank positioned relative to the pump in one of three configurations for coupling fluid connections to fluid conduits from one or more external sources; a refrigeration module comprising: a condenser extending diagonally across the refrigeration module and dividing the refrigeration module into two regions, wherein each region comprises two sides; a heat exchanger located in a first region; and a fan positioned on a first side in a second region opposite the heat exchanger; a plurality of panels, comprising: an air permeable panel positioned on at least one of a first side or a second side of the two sides in the first region, wherein air flow passes through the refrigeration module via the air permeable panel; and a nonpermeable panel positioned on a second side in the second region, wherein the nonpermeable panel prevents air flow through the second side, wherein air flow passes from the first region through the condenser to the fan; and an electronics module coupled to the refrigeration module in a configuration based on user access to the process chiller. In some embodiments, the tank comprises a front wall and at least one side wall, wherein the at least one side wall is configured for user access to fluid connections in any one of the three configurations. In some embodiments, the tank comprises the front wall and two side walls, wherein each side wall is angled for access to the fluid connections. In some embodiments, the tank comprises at least a front wall and at least one curved wall, wherein the curved wall comprises a curvature for access to the fluid connections. In some embodiments, the processing system comprises a process machine, wherein an enclosure of the process machine comprises at least a part of the nonpermeable panel. In some embodiments, the processing system includes a process machine, wherein at least a portion of the air flows through the process machine.
Certain embodiments may provide one or more technical advantages. For example, embodiments of the present disclosure allow a manufacturer to manufacture a limited number of process chiller modules but offer a large number of variations of process chillers, wherein each variation can be configured based on customer requirements related to fluid connections and proximity to other machines in the process.
Certain embodiments may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and claims included herein.
For a more complete understanding of the present disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
Embodiments of the present disclosure and its advantages are best understood by referring to
A process chiller cools fluids received from one or more machines in a processing system and supplies the one or more machines with cooled fluids.
An electronics control module 110 is capable of sensing temperature, flow rate and other characteristics of fluid received by the process chiller and controlling the temperature, flow rate and fluid pressure of the cooled fluids supplied by the process chiller. In some embodiments, the electronics module 110 is capable of receiving manual inputs and operating independently of other machines in the processing system. In some embodiments, the electronics module 110 is communicatively coupled to at least one machine in the processing system such that the electronics module 110 is configured to adjust operating parameters of the fluid module 130 or the refrigeration module 120 based on a received signal from the machine in the processing system.
A fluid module receives heated fluids from the processing system, pumps fluids throughout the process chiller to cool the fluid, stores the fluid if needed, and supplies cooled fluids to one or more machines in the processing system.
A refrigeration module 120 includes a fan 126 to draw air flow across a heat exchanger 123 and a condenser 122 to cool fluids received from the one or more machines in the processing system to a preselected temperature.
Embodiments allow a manufacturer to manufacture all variations of refrigeration module 120 with selected components 123, 124 and 125 in the same position, and refrigeration module 120 may be coupled to fluid module 130 in various configurations. For example, as depicted in
To control airflow though refrigeration module 120, a nonpermeable panel is positioned on any one or more of sides 128A, 128B and 128D.
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Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. For example, refrigeration system 100 may include any suitable number of compressors, condensers, condenser fans, evaporators, valves, sensors, controllers, and so on, as performance demands dictate. One skilled in the art will also understand that refrigeration system 100 can include other components that are not illustrated but are typically included with refrigeration systems. Additionally, operations of the systems and apparatuses may be performed using any suitable logic comprising software, hardware, and/or other logic. As used in this document, “each” refers to each member of a set or each member of a subset of a set.
Modifications, additions, or omissions may be made to the methods described herein without departing from the scope of the disclosure. The methods may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.
Although this disclosure has been described in terms of certain embodiments, alterations and permutations of the embodiments will be apparent to those skilled in the art. Accordingly, the above description of the embodiments does not constrain this disclosure. Other changes, substitutions, and alterations are possible without departing from the spirit and scope of this disclosure.
Number | Date | Country | |
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62901103 | Sep 2019 | US |