We designed and installed a refrigerant mixing device for Danfoss’s compressor testing setup to improve safety and reliability during operation. A critical risk in compressor testing occurs when liquid refrigerant enters the compressor. Since liquids cannot be compressed, this can cause serious mechanical damage. Our goal was to mitigate this risk while integrating seamlessly with Danfoss’s existing system for evaluating cooling and refrigeration compressors.
Over two semesters, we researched refrigerant behavior, reviewed existing solutions and evaluated multiple design concepts before selecting a final approach. We used design software to model and refine device geometry, and ran computer simulations to predict refrigerant flow and mixing behavior prior to physical testing. Key design targets included reliable operation across a range of conditions, a total cost of approximately $2,000 and straightforward manufacturing and assembly to simplify integration with the existing test setup.
We selected a device with a spiral interior geometry, which continuously mixes refrigerant as it flows through, preventing liquid accumulation and improving flow consistency. The absence of moving parts reduces maintenance requirements and minimizes failure risk. After building and testing a prototype, we installed the final device on Danfoss’s testing system. The design meets all performance requirements while remaining affordable and easy to manufacture. By preventing liquid refrigerant from reaching the compressor, our device improves operational safety, protects valuable equipment and helps ensure the accuracy of compressor test results.
