CHILLER ASSEMBLY

Abstract

A chiller assembly includes an enclosure having a separator panel provided therein that divides the enclosure into first and second compartments. The separator panel is mounted at an angle relative to the horizontal. A condenser is provided with the first compartment. A heat exchanger is provided with the second compartment. The heat exchanger and the condenser utilize refrigerant flowing therebetween to remove heat from a supply of fluid flowing through the heat exchanger. The enclosure includes a debris opening to provide access to debris collected on the separator panel when one of air and fluid is directed through the condenser in a direction towards the separator panel during a cleaning operation of the condenser.

Description

BACKGROUND OF THE INVENTION

This invention relates in general to industrial or medical coolant chiller assemblies. Chiller assemblies are used in conjunction with processes or applications as heat exchangers for removing heat from fluids. Chilled fluid is delivered by the chiller assembly to the process. The process increases the temperature of the fluid. The fluid is then returned to the chiller assembly, where the fluid is cooled and then again delivered to the process. Thus, the fluid is cycled between the chiller assembly and the process. Various examples of processes or applications that utilize chilled fluids include machine tool equipment, lasers, water jet cutting tools, medical equipment, food systems, chemical systems, heat treatment equipment, filtration systems, semi-conductor systems, welding processes, vapor degreasing systems, power generation, and dry cleaning equipment. Common fluids that are used include water, water/glycol, coolant fluids, lubricants, oils, acids, EDM (electrical discharge machining) fluids, and gasoline.

Chiller assemblies are generally designed to deliver the fluid to the process or application at a desired temperature. Typical chiller assemblies include a closed loop heat exchange system using a refrigerant to remove heat from the fluid. The heat exchange systems generally include a condenser, a heat exchanger and/or evaporator, and a motor driven compressor. These components are housed in an enclosure, which typically includes a top mounted exhaust fan. The condenser includes conduits such as coils, a plurality of tubes, or a series of plates through which the refrigerant flows through. The conduits are mechanically connected to a plurality of metal fins such that the conduits are cooled by air forced over the fins and conduits by the exhaust fan. The cooling of the conduits generally causes the refrigerant flowing inside the conduits to condense from a warmer gaseous state to a cooler liquid state. The cooled liquid refrigerant then is directed to the evaporator or heat exchanger, where the cooled liquid refrigerant is used to lower the temperature of the fluid. After the heat exchange within the evaporator or heat exchanger, the now-heated refrigerant is directed back to the condenser, while the cooled process fluid is directed back to the process. Thus, the heat from the fluid is removed by the air which is forced over the fins and conduits by the exhaust fan. Typically, the condenser is a mounted in a side opening formed in the enclosure of the coolant chiller assembly. The exhaust fan may be mounted in an upper opening formed in a top roof panel of the enclosure. The exhaust fan pulls air through the side opening and through the condenser, then exhausts the heated air through the upper opening.

After a period of use, the conduits and fins of the condenser may accumulate dust, dirt, and foreign matter which unfortunately act as an insulative coating, thereby reducing the efficiency of the condenser. This dust, dirt, and foreign matter also may restrict the air flow though the condenser. The reduced efficiency may be even worse for condensers which are made from aluminum compared to ones made from copper due to their generally smaller, thinner, and more compact design. In the past, the condensers were cleaned by directing, air, water, or other fluid at the condenser to release the dust, dirt, and foreign matter. However, the newly released dust, dirt, and foreign matter can form debris which may inadvertently be directed at the evaporator, compressor, motors, and other components within the coolant chiller enclosure. To avoid contaminating the components, the condenser may be removed and then cleaned. However, this is also undesirable due to the time involved, and it further prevents the coolant chiller from being used during cleaning.

SUMMARY OF THE INVENTION

This invention relates to chiller assemblies and, in particular, to a chiller assembly that includes an enclosure having a separator panel provided therein that divides the enclosure into first and second compartments. The separator panel is mounted at an angle relative to the horizontal. A condenser is provided within the first compartment. A heat exchanger is provided within the second compartment. The heat exchanger and the condenser utilize refrigerant flowing therebetween to remove heat from a supply of fluid flowing through the heat exchanger. The enclosure includes a debris opening to provide access to debris collected on the separator panel when one of air and fluid is directed through the condenser in a direction towards the separator panel during a cleaning operation of the condenser.

Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a first embodiment of a chiller assembly.

FIG. 2 is a rear perspective view of the enclosure of the chiller assembly of FIG. 1.

FIG. 3 is a front elevational view of the enclosure of FIG. 2.

FIG. 4 is a side view of the enclosure of FIG. 2.

FIG. 5 is an enlarged partial cross-sectional view taken along lines 5-5 of FIG. 3 illustrating a hinged debris door mounted on the enclosure.

FIG. 6 is schematic a side elevational view of a second embodiment of an enclosure.

FIG. 7 is a schematic side elevational of a third embodiment of an enclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, there is illustrated in FIG. 1 a first embodiment of a chiller assembly, which is indicated generally at 10. The assembly 10 may be used to cool any type of fluid for use in a process or machine. The fluid enters the assembly 10 at an inlet conduit 12 and exits the assembly 10 at an outlet conduit 14. The assembly removes heat from the fluid entering the inlet conduit 12 and discharges the fluid at the outlet conduit 14 at a desired temperature or at a desired temperature differential. Hoses or conduits (not shown) can be connected to the inlet and outlet conduits 12 and 14 and connected to the various machines and processes. It should be understood that the assembly 10 can be used with any application, machine, or process which utilizes fluids. Examples of processes or applications that may be used with the assembly 10 include machine tool equipment, lasers, water jet cutting tools, medical equipment, food systems, chemical systems, heat treatment equipment, filtration systems, semi-conductor systems, welding processes, vapor degreasing systems, power generation, and dry cleaning equipment. It should also be understood that any fluid may be used between the assembly 10 and the process. Examples of such fluids include water, water/glycol, coolant fluids, lubricants, oils, acids, EDM (electrical discharge machining) fluids, gasoline, and other fuels. In just one possible example, the inlet and outlet conduits 12 and 14 of the assembly 10 may be connected with a machine tool (not shown) which sprays the fluid directed at a workpiece and a cutting tool. The fluid provides lubrication, removes metal chips, and cools the cutting tool and workpiece during a cutting or machining operation. The fluid is sprayed onto the cutting tool and workpiece and collected afterwards. The collected fluid is then sent to the assembly 10, where the fluid is cooled and then delivered back to the machine tool.

The assembly 10 includes an enclosure 20 which houses various components of the assembly 10. As shown in FIGS. 1 through 4, the enclosure 20 can have a generally rectangular box-like shape. Of course, the enclosure 20 can have any suitable shape for housing the components. The enclosure 20 can be formed from any material, such as generally flat metal sheeting which may be riveted, welded, glued or otherwise connected together. The illustrated enclosure 20 includes a front wall 22, a rear wall 24, left and right sides 26 and 28, a top panel 30, and a lower panel 32. The enclosure 20 may also include feet 33 to slightly raise the lower panel 32 from the floor which the assembly 10 is resting on. The enclosure 20 also includes a separator panel 34 mounted within the interior of the enclosure 20. The separator panel 34 may be generally mounted on an angle relative to the horizontal, the reason for which will be explained below. The separator panel 34 separates the interior of the enclosure 20 into two compartments: a condenser compartment 36 and a component compartment 38. More details of the enclosure 20 will be explained below.

The assembly 10 also includes a condenser 40, an exhaust fan 42, and a control panel 44, as shown in FIG. 1. As schematically shown in FIG. 4, the assembly 10 also generally includes a heat exchanger assembly 46, a compressor 48, and a motor 50 for driving the compressor 48. The assembly 10 may also include a pump 51. The control panel 44 may be connected to a power source (not shown) and can include controls and gauges for controlling the various components of the assembly 10. The condenser 40 and the exhaust fan 42 are generally mounted within the condenser compartment 36. Alternatively, the condenser 40 and the exhaust fan 42 may be partially located within the condenser compartment 36 or mounted on the exterior of the enclosure 20. The heat exchanger assembly 46, the compressor 48, and the motor 50 are generally located within the component compartment 38. The pump 51 cycles the fluid through the inlet and outlet conduits 12 and 14, thereby delivering the fluid between the desired application or process and the chiller assembly 10. The pump 51 may be provided as part of the assembly 10 or alternatively may be provided with the process and, thus, not housed within the enclosure 20.

In the embodiment shown in FIGS. 1 through 5, the condenser 40 has a relatively flat planar shape and is housed adjacent an opening 60 formed in the front wall 22 of the enclosure 20. The opening 60 communicates with the condenser compartment 36. The condenser 40 may be formed as a conventional condenser unit including a plurality of relatively narrow conduits, through which refrigerant flows through. The conduits may be formed as small passageways formed in structures with a relatively large collective outer surface. Examples of suitable conduits are coils, a plurality of tubes, or series of plates. The conduits may be arranged in a coil-like pattern such that the refrigerant flows through a single path. Alternatively, the conduits can be arranged such that there are multiple flow paths. The condenser 40 may also be configured such that a plurality of generally thin fins is connected to the conduits. The fins function as heat sinks and help provide heat transfer when air flows past the heat fins and conduits. The condenser 40 may be supported within the enclosure 20 by supports 62 attached to the inside face of the front wall 22. In the illustrated embodiment, there is provided a pair of supports 62 formed from bent and shaped sheet metal. The supports 62 are attached to a lower portion 66 of the separator panel 20, as best shown in FIG. 5.

The top panel 30 includes an opening 68 formed therein. The opening 68 communicates with the condenser compartment 36. The exhaust fan 42 may be mounted on the enclosure 20 adjacent the opening 68. The exhaust fan 42 may be mounted above the top panel 30, as shown in FIG. 1, below the top panel 30, or within the opening 68. It should be understood that the opening 68 and exhaust fan 42 may be located on any exterior panel or wall of the enclosure 20.

During operation of the coolant chiller assembly 10, the exhaust fan 42 provides air flow into the enclosure 20 through the opening 60, through the condenser 40, and out of the enclosure 20 through the opening 68. Thus, air is directed over the conduits and fins of the condenser 40. The flow of air over the conduits and fins provides for heat transfer between the fluid within the conduits and the ambient air. The compressor 48 is operated to pump refrigerant through the conduits of the condenser 40. Cooling of the conduits causes the refrigerant therein to cool and to condense from a warmer gaseous sate to a cooler liquid state. The cooled liquid refrigerant then is directed to an evaporator of the heat exchanger assembly 46 where the cooled liquid refrigerant is used to lower the temperature of the fluid. The heat exchanger assembly 46 includes separate conduits containing the refrigerant and the fluid which are positioned adjacent one another for heat exchange purposes. The fluid and the refrigerant are generally not commingled. After the heat exchange, the now-heated refrigerant is directed back to the condenser 40, while the cooled fluid is directed back to the process or machine.

It is sometimes desirable to clean the condenser 40 after a period of time to remove dust, dirt, and foreign matter which may accumulate on the conduits and fins thereof. The condenser 40 can be cleaned by directing, air, water, or other fluid in a direction at a front face 70 of the condenser 40 to release the dust, dirt, and foreign matter on the conduits and fins of the condenser 40. The air, water, or other fluid may be directed by an applicator 72 as shown schematically in FIG. 1. The applicator 72 can be a spray gun or hose which forces air, water or other fluid at a relatively high velocity at the condenser 40. The applicator 72 is simply manually moved to direct the spray across the face 70 of the condenser 40 to dislodge the dust, dirt, and foreign matter from the surfaces of the conduits and fins of the condenser 40. The dislodged dust, dirt, and foreign matter, as well as the water or fluid if so used, form debris which is dispersed within the interior of the condenser compartment 36. The separator panel 34 provides a barrier between the dispersed debris and the various components housed within the component compartment 38 of the assembly 10. The separator panel 34 is preferably mounted at a non-zero degree angle relative to the horizontal such that gravity will collect the debris on the separator panel 34. The shape and/or angled mounting of the separator panel 34 may also assist in moving the debris downwardly to a collection region 76, as best shown in FIG. 5. The collection region 76 may simply be adjacent the lower portion 66 of the separator panel 34. The collection region 76 may be below a lower edge 41 of the condenser 40 such that debris removed from the lower portion of the condenser 40 will collect on the separator panel 34 and be moved to the collection region 76. To easily remove the debris from the collection region 76, the enclosure 20 may have a debris opening 80 formed therein. In the illustrated enclosure 20, the debris opening 80 is a slot located under the lower edge of the condenser 40 and generally extends to the sides of the enclosure 20. The debris opening 80 may have the same general width as the width of the front face 70 of the condenser 40. The enclosure 20 may also include a door 84 movably mounted on the enclosure 20 for selectively covering and exposing the debris opening 80. The door 84 may be mounted by a hinge 86 connected to an upper portion of the door 84. The door 84 may be simply lifted upwardly to a position (indicated by 84′) to remove the debris from the collection region 76. Since the debris opening 80 is in communication with the condenser compartment 36, the door 84 is preferably in its closed position during operation of the assembly 10 to help prevent air flow through the debris opening 80. Thus, the door 84 provides for an easy manner for removing the debris during a cleanout operation, while maintaining air flow efficiency during operation of the assembly 10.

In the embodiment of the enclosure 20 illustrated in FIGS. 1 through 5, the separator panel 34 extends across the entire width of the enclosure 20 and is attached to the side panels 26 and 28 of the enclosure 20. Side edges 88 of the separator panel 34 may be attached to the side panels 26 and 28 by riveting mounting flanges 90 formed along the side edges 88 of the separator panel 34 to the side panels 26 and 28 of the enclosure 20. The mounting flanges 90 may be simply an edge portion of the side edges 88 which are bent at a ninety degree angle. Also, an upper edge 92 of the separator panel 34 may extend all the way to the rear wall 24 and/or the top panel 30 of the enclosure 20. A lower edge 94 of the separator panel 34 may also extend all the way to the front wall 22 of the enclosure 20. In this configuration, the separator panel 34 substantially seals the condenser compartment 36 from the component compartment 38. This may be advantageous in that the sealed configuration prevents debris from entering the component compartment 38 during a cleaning operation and also provides for an efficient air flow path though the condenser 40 when the exhaust fan 42 moves air from the opening 60 out through the upper opening 68. However, it should be understood that the separator panel 34 may be sized and configured such that none, one, or more than one of the side edges 88, the upper edge 92, or the lower edge 94 does not attach directly to one of the outer walls of the enclosure 20, thereby leaving a gap and, therefore, not sealing the compartments 36 and 38 from one another. This may be advantageous if some air flow is desired through the component compartment 38 for cooling off the components therein. Thus, while the separator panel 34 separates and defines the condenser compartment 36 and the component compartment within the interior of the enclosure 20, the two compartments 36 and 38 need not be fully sealed from one another, although they may be if so desired. Also, the enclosure 20 may further include other compartments therein which are separated from the condenser compartment 36 or the component compartment 38 from other panels (not shown). The enclosure 20 may also include vent openings, such as openings 97 formed through the rear wall 24, to provide ventilation of the component compartment 38.

The separator panel 34 may be formed by a single part, such as a single sheet as shown in the illustrated embodiment in FIGS. 1 through 5, or may be formed from a plurality of parts connected together or individually connected to various structures of the enclosure 20. As shown in FIG. 5, the lower portion 66 of the separator panel 34 may be slightly angled from the main portion of the separator panel 34 at a bend 98 to accommodate the mounting of the separator panel 34 to the supports 62 and the walls of the enclosure 20.

The separator panel 34 may be made of any suitable material, such as sheet metal. However, it should be understood that any material, such as plastic, may be used instead. The separator panel 34 may also include a coating or outer layer to reduce the adhesion of debris thereto so that the debris is more likely to slide downwardly into the collection region 76.

In the embodiment of the enclosure 20 illustrated in FIGS. 1 through 5, the separator panel 34 has generally flat planar shape. It should be understood that the separator panel 34 may have any suitable shape which preferably functions to separate the enclosure 20 into the condenser compartment 36 and the component compartment 38 while also directing any debris to the collection region 76. If the separator panel 34 is angled relative to the horizontal, gravity may assist in capturing and then sliding any debris downwardly along an upper surface 35.

The separator panel 34 may have a curved or sloped shape either in the side direction or front-to-rear direction. For example, there is schematically illustrated in FIG. 6 an alternate embodiment of a chiller assembly 100 having an enclosure 101 including a differently shaped separator panel 102. In the embodiment illustrated in FIG. 6, the separator panel 102 has a curved or sloped shape. The separator panel 102 is shaped to permit gravity to direct any debris collected thereon downwardly. Debris is directed to a collection region 104 under the lower edge 106 of the condenser 108.

Another difference of the enclosure 101 compared to the enclosure 20 is that instead of a hinged door 84, the enclosure 101 includes a movably mounted collection tray 110. The tray 110 may be slidably mounted along a track 112 or may be movably mounted by any other suitable mounting arrangement. The illustrated embodiment of the tray 110 includes a front wall 114 which selectively covers a debris opening 116. The tray 110 can be moved to a position indicated by 110′ or can be completely removed to dump the debris after a cleanout operation. The tray 110 can have any suitable shape. For example, the tray 110 may be in the form of a drawer having a bottom panel and one or more vertical side walls. The tray 110 may also be a flat plate. The tray 110 may also include a funnel shaped portion (not shown) which collects debris in a localized area. A conduit or hose may be connected to the funnel portion for directing the debris to a desired holding area or drainage area. The tray 110 may also be any size for collecting and removing debris. For example, the tray 110 may be located under a lower portion 113 of the separator panel 102 and sized to fit in the collection region 104. Alternatively, the tray 110 may extend in a longer direction towards the rear of the enclosure 100. In an alternative embodiment not shown, the tray and separator panel may be combined as a unit such that a portion or the entire separator panel may be removed from the enclosure to easily dispose of the debris.

The separator panel 102 divides the interior of the enclosure 101 into a condenser compartment 120 and a component compartment 122. It is noted that the lower portion 113 of the separator panel 102 does not extend all the way to a front wall 124 of the enclosure 101. Thus, the separator panel 102 does not completely seal the condenser compartment 120 from the component compartment 122. However, this configuration still permits airflow, as represented by arrow 126, through the condenser 108 by an exhaust fan (not shown) in a similar manner as described above with respect to the assembly 10.

The enclosure 101 may also be configured such that the tray 110 is removed from a side wall, rear wall, or top panel of the enclosure 101 instead of the front wall 124. For example, the enclosure 101 could be configured with a side opening formed in the side wall of the enclosure 101 instead of the opening 116 in the front wall 124.

There is illustrated in FIG. 7 another embodiment of a coolant chiller assembly 130 having an enclosure 132 and a pair of condensers 134. During operation of the assembly 130, air flow, as represented by arrows 133, flows through the condenser 108 by an exhaust fan (not shown) in a similar manner as described above with respect to the assembly 10. The enclosure 132 further includes a separator panel 136 having an inverted V-shape such that there are two collection regions 139. The separator panel 136 defines a pair of downwardly sloping portions 137. The collection regions 139 are located adjacent respective debris openings 140 having hinged doors 142 functioning in a similar manner as the enclosure 20 described above.

The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Claims

1. A chiller assembly comprising:

an enclosure having a separator panel provided therein that divides said enclosure into first and second compartments and that is mounted at an angle relative to the horizontal,

a condenser provided within said first compartment; and

a heat exchanger provided within said second compartment, wherein said heat exchanger and said condenser utilize refrigerant flowing therebetween to remove heat from a supply of fluid flowing through said heat exchanger;

wherein said enclosure includes a debris opening to provide access to debris collected from said separator panel.

2. The assembly of claim 1, wherein the debris opening is located below said condenser and adjacent a lower portion of said separator panel for collecting debris when one of air and fluid is directed through said condenser in a direction towards said separator panel during a cleaning operation of said condenser.

3. The assembly of claim 1, wherein the enclosure includes a removable debris tray located adjacent said debris opening.

4. The assembly of claim 1, wherein said enclosure includes a door movably mounted on said enclosure for selectively covering and exposing said debris opening.

5. The assembly of claim 1, wherein said enclosure includes a vertically oriented front panel, said front panel having said debris opening and an opening receiving said condenser formed therein.

6. The assembly of claim 1, wherein said separator panel has a flat planar shape.

7. The assembly of claim 1, wherein said separator panel has a curved shape.

8. The assembly of claim 1, wherein said separator panel is formed from a single panel.

9. The assembly of claim 1, wherein said separator panel seals said first compartment from said second compartment such that the debris will not be introduced into said second compartment during the cleaning operation.

10. The assembly of claim 1, wherein said condenser is vertically mounted in said first opening.

11. The assembly of claim 1 further including an exhaust fan mounted in a second opening of said enclosure, wherein said second opening communicates with said first compartment.

12. A chiller assembly comprising:

an enclosure having a separator panel provided therein that divides said enclosure into first and second compartments and that is mounted at an angle relative to the horizontal, said separator panel sealing said first compartment from said second compartment;

a condenser provided within said first compartment;

an exhaust fan mounted in a second opening of said enclosure, wherein said second opening communicates with said first compartment;

a heat exchanger provided within said second compartment, wherein said heat exchanger and said condenser utilize refrigerant flowing therebetween to remove heat from a supply of fluid flowing through said heat exchanger;

wherein said enclosure includes a debris opening located below said first opening to provide access to debris collected on said separator panel when one of air and fluid is directed through said condenser in a direction towards said separator panel during a cleaning operation of said condenser, and wherein said enclosure includes a door movably mounted on said enclosure for selectively covering and exposing said debris opening.

13. A chiller assembly comprising:

an enclosure defining an interior;

a separator panel disposed within the interior of the enclosure and dividing the interior of the enclosure into first and second compartments, the separator panel being oriented at an angle relative to the horizontal;

a removable debris tray provided within said first compartment;

a condenser provided within the first compartment; and

a heat exchanger provided within the second compartment and in fluid communication with the condenser, the condenser and the heat exchanger adapted to lower the temperature of a fluid passing through the heat exchanger.

14. The assembly of claim 13, wherein said debris tray is located adjacent a bottom portion of said separator panel for collecting debris when one of air and fluid is directed through said condenser in a direction towards said separator panel during a cleaning operation of said condenser.