An integrated overhead chiller device
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-24
- Publication Date
- 2026-08-11
AI Technical Summary
[0005]本方案的原理及优点是：本实用新型的顶置一体式冷机装置通过电气控制系统与制冷系统的协同创新设计，成功解决了车载环境下电源不稳定对制冷设备造成的严重影响，实现了在极端电压波动条件下依然保持高效稳定运行
[0005]The principle and advantages of this solution are as follows: This utility model's top-mounted integrated chiller unit, through the collaborative innovative design of the electrical control system and the refrigeration system, successfully solves the serious impact of unstable power supply on refrigeration equipment in the vehicle environment, achieving efficient and stable operation even under extreme voltage fluctuation conditions. In practical applications, by designing a power adapter module adapted to 65V-144V DC input, combined with a voltage stabilization module and an intelligent protection module, the chiller unit can still operate normally under harsh conditions where the voltage drops sharply from 144V to around 60V at the moment of vehicle startup. This electrical control system architecture effectively solves the problems of control circuit self-test failure and insufficient compressor starting torque caused by the surge in vehicle starting current demand in traditional top-mounted chillers. It can also adapt to voltage fluctuations of 120V-150V caused by load changes during vehicle operation, significantly improving the system's stability and reliability in complex vehicle environments. This utility model is the first to combine wide-range DC adapter, supercapacitor voltage stabilization, and intelligent soft start in a top-mounted integrated chiller, specifically targeting a 4m... 3 This design addresses the issue of unstable 144V power supply through spatial design; by coordinating the design of electrical control and refrigeration systems, stable operation under voltage fluctuations is achieved. This invention is suitable for refrigeration needs in small spaces such as refrigerated trucks and small cold storage facilities, solving the problem of unstable 144V DC power supply in vehicles, improving the reliability and service life of the refrigeration unit, and has broad industrial application prospects.
Smart Images
Figure CN224617382U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of refrigeration equipment technology, specifically to a top-mounted integrated refrigeration unit. Background Technology
[0002] Roof-mounted refrigeration units are widely deployed in refrigeration scenarios of various small refrigerated transport vehicles due to their compact structure, simple and quick installation, and the fact that they do not occupy valuable loading or chassis space under the vehicle. However, these devices typically rely on the vehicle's own 144V DC battery system as their power source. At the moment of vehicle startup, due to the surge in starting current demand, the battery output voltage often drops sharply from the rated 144V to 60V or even lower. This sudden drop can easily cause the refrigeration unit's control circuit to fail the power-on self-test, and also makes it difficult for the compressor to start normally due to significantly insufficient starting torque. Furthermore, during actual vehicle operation, dynamic changes in electrical loads—such as the starting and stopping of the vehicle's air conditioning and the switching on and off of lights—can cause frequent fluctuations in the supply voltage between 120V and 150V. This continuous voltage instability can easily cause irreversible damage to critical electronic components in the control circuit (such as relays and voltage sensors). On the other hand, traditional top-mounted chillers are usually only equipped with simple fuses as overcurrent protection measures in their design, lacking adaptation and buffering mechanisms for wide-range voltage changes. As a result, they are difficult to effectively suppress the negative impact of voltage fluctuations, which ultimately leads to a significant reduction in the service life of core components such as compressors and evaporator fans, and a decrease in the overall reliability of the system. Utility Model Content
[0003] The present invention aims to provide a top-mounted integrated chiller device, which adopts a wide-range DC input compressor and converts it to low-pressure regulated output through DC direct drive for use by low-pressure loads.
[0004] To achieve the above objectives, this utility model adopts the following technical solution: a top-mounted integrated refrigeration unit, comprising a refrigeration system and an electrical control system. The refrigeration system includes a compressor, a condenser plate, an evaporator, an expansion valve, a condenser fan, an evaporator fan, a solenoid valve, and a horizontal drying bottle. The electrical control system includes a power adapter module, a voltage stabilization module, an intelligent protection module, and a relay box. The power adapter module is compatible with 65V-144V DC input. The voltage stabilization module is electrically connected to the power adapter module. The intelligent protection module is electrically connected to the voltage stabilization module and the relay box. The relay box is electrically connected to each component of the refrigeration system.
[0005] The principle and advantages of this solution are as follows: This utility model's top-mounted integrated chiller unit, through the collaborative innovative design of the electrical control system and the refrigeration system, successfully solves the serious impact of unstable power supply on refrigeration equipment in the vehicle environment, achieving efficient and stable operation even under extreme voltage fluctuation conditions. In practical applications, by designing a power adapter module adapted to 65V-144V DC input, combined with a voltage stabilization module and an intelligent protection module, the chiller unit can still operate normally under harsh conditions where the voltage drops sharply from 144V to around 60V at the moment of vehicle startup. This electrical control system architecture effectively solves the problems of control circuit self-test failure and insufficient compressor starting torque caused by the surge in vehicle starting current demand in traditional top-mounted chillers. It can also adapt to voltage fluctuations of 120V-150V caused by load changes during vehicle operation, significantly improving the system's stability and reliability in complex vehicle environments. This utility model is the first to combine wide-range DC adapter, supercapacitor voltage stabilization, and intelligent soft start in a top-mounted integrated chiller, specifically targeting a 4m... 3 This design addresses the issue of unstable 144V power supply through spatial design; by coordinating the design of electrical control and refrigeration systems, stable operation under voltage fluctuations is achieved. This invention is suitable for refrigeration needs in small spaces such as refrigerated trucks and small cold storage facilities, solving the problem of unstable 144V DC power supply in vehicles, improving the reliability and service life of the refrigeration unit, and has broad industrial application prospects.
[0006] Preferably, as an improvement, the power adapter module includes a rectifier filter circuit for filtering the input DC power supply, a fuse for overcurrent protection, a TVS diode for overvoltage protection, and an undervoltage protection circuit for cutting off the power supply when the voltage is below 65V.
[0007] Preferably, as an improvement, the voltage stabilization module includes a DC-DC regulator and a supercapacitor; the supercapacitor is connected in parallel to the output terminal of the power adapter module to absorb energy during voltage drops.
[0008] Preferably, as an improvement, the intelligent protection module includes a microcontroller, a voltage detection circuit, and a soft-start circuit; the microcontroller is used to receive voltage detection signals and output control commands; the voltage detection circuit is used to detect the voltage at the output terminals of the power adapter module and the voltage stabilization module; the soft-start circuit is used to gradually increase the compressor current and decrease the starting current by using a PWM signal when the compressor starts.
[0009] Preferably, as an improvement, the intelligent protection module further includes a fault alarm unit; when the voltage fluctuation exceeds ±15%, the intelligent protection module cuts off the compressor power supply and records the fault.
[0010] Preferably, as an improvement, in the refrigeration system, the compressor's exhaust port is connected to the inlet of the condenser plate, the condenser plate's outlet is connected to the inlet of the horizontal dryer bottle, the horizontal dryer bottle's outlet is connected to the inlet of the expansion valve, the expansion valve's outlet is connected to the inlet of the evaporator, and the evaporator's outlet is connected to the compressor's return port; the condenser fan is located on the air outlet side of the condenser plate, the evaporator fan is located on the air outlet side of the evaporator, and the solenoid valve is located on the pipeline before the expansion valve's inlet.
[0011] Preferably, as an improvement, the compressor and condenser are located at one end of the device, and the evaporator is located at the other end, with the electrical control system arranged in the middle area. The condenser has a microchannel parallel flow structure, including multiple layers of aluminum flat tubes and corrugated fins. The dryer bottle is horizontally installed and directly connected between the condenser outlet and the expansion valve inlet, forming a low-resistance channel. In terms of the refrigeration system, the device adopts an optimized fluid path design and spatial layout, concentrating the compressor and condenser at one end, the evaporator at the other end, and the electrical control system in the center, significantly shortening the refrigerant piping length and reducing pressure loss and energy consumption. The combined design of the microchannel parallel flow condenser and the stacked evaporator improves heat exchange efficiency; the low-resistance connection of the horizontal dryer bottle further optimizes the refrigerant flow characteristics, improving the system's energy efficiency ratio.
[0012] Preferably, as an improvement, the evaporator has a stacked structure, including an evaporation core, a water receiving tray, and a drain pipe; the evaporation core is provided with a hydrophilic coating, the bottom of the water receiving tray is inclined, and the lowest point is connected to the drain pipe.
[0013] Preferably, as an improvement, it also includes an integrated housing, wherein the top of the housing has an air inlet and an air outlet, and the side has a maintenance window; the interior of the housing has a partition that separates the refrigeration system and the electrical control system into two independent chambers, each with an independent heat dissipation channel; the partition has sealed wire holes for electrical connection and to prevent refrigerant leakage into the electrical control chamber. The integrated housing separates the refrigeration system and the electrical control system into two independent chambers through the internal partition, each with its own independent heat dissipation channel, effectively preventing mutual interference; the sealed wire hole design eliminates the risk of refrigerant seeping into the electrical components; the optimized top air inlet / outlet and side maintenance window balance heat dissipation efficiency and maintenance convenience, reducing operating noise. All components are integrated into the top structure of the integrated housing, making installation convenient and suitable for 4m... 3 The space is similar to the top of a small refrigerated truck's cargo box, without taking up interior space. Attached Figure Description
[0014] Figure 1 This is an electrical control schematic diagram of an embodiment of the present utility model.
[0015] Figure 2 This is a structural schematic diagram of an embodiment of the present utility model. Detailed Implementation
[0016] The following detailed description illustrates the specific implementation method: The reference numerals in the accompanying drawings include: 1. Condenser fan; 2. Condenser plate; 3. Horizontal drying bottle; 4. Two-in-one assembly; 5. Expansion valve; 6. Electrical box; 7. Evaporator fan; 8. Evaporator; 9. Solenoid valve; 10. Compressor; 11. Relay box.
[0017] The basic implementation examples are as follows: Figure 1 As shown: The specific implementation process is as follows: The top-mounted integrated refrigeration unit is fixed to the top of the cargo box and connected to the vehicle's 144V DC power supply (positive terminal connected to the "+144V" terminal of electrical box 6, negative terminal connected to the "GND" terminal). After power-on, the power adapter module detects the voltage (144V). If the voltage is normal, the microcontroller starts up and the sensors perform self-tests. The refrigeration system and electrical control system are integrated within the top-mounted metal frame, and all components are arranged according to functional zones, effectively shortening pipe length and reducing refrigeration losses. Electrical box 6 and relay box 11 are both integrated inside the frame for easy wiring and daily maintenance.
[0018] like Figure 1 As shown, the electrical control system includes a power adapter module, a voltage stabilization module, and an intelligent protection module. The connection relationships and functions of each module are as follows: Power adapter module: After connecting to a 144V DC power supply, the power supply first passes through a rectifier and filter circuit (including capacitors and inductors) to filter out noise. Then, overcurrent protection is achieved through a fuse (rated current of 15A). Next, overvoltage clamping is performed using a TVS diode (breakdown voltage of 150V) to prevent excessive voltage from damaging subsequent circuits. Finally, the undervoltage protection circuit (composed of a comparator and a MOSFET) automatically cuts off the power supply when the voltage is below 65V to avoid malfunctions in the control circuit.
[0019] Voltage stabilization module: The DC voltage output from the power adapter module is input to the DC-DC regulator (input range 65V-144V, output 12V / 380V) to provide power to the control circuit (including the microcontroller and sensors) and the compressor 10 respectively; the supercapacitor (capacity 1000F, withstand voltage 150V) is connected in parallel to the power output terminal to absorb the energy of the voltage drop generated when the vehicle starts (for example, when the voltage drops from 144V to 80V, the supercapacitor discharges to replenish the current and ensure the torque required for the compressor to start).
[0020] Intelligent Protection Module: This module uses a microcontroller (STM32F103) as its core and monitors the power supply voltage in real time through a voltage detection circuit (voltage divider resistors + ADC acquisition). The soft-start circuit (IGBT + PWM generator) gradually increases the IGBT duty cycle during compressor startup (from 0 to 100% in at least 3 seconds) to reduce the starting current (from 1.5 times the rated current to 1 times). The fault alarm unit (buzzer + LED indicator) triggers an audible and visual alarm when the voltage is abnormal (below 80V or above 130V), reminding the user to check the power supply. The load adjustment unit reduces the speed of condenser fan 1 and evaporator fan 7 to 50% via PWM signals when the voltage exceeds 130V, thereby reducing load current and stabilizing the voltage.
[0021] The specific operating steps of the top-mounted integrated chiller unit are as follows: Step 1: DC Power Supply and System Initialization. Connect a 65V - 144V DC power supply to the electrical box. Control circuit #6. Power is distributed through relays and protection components (such as fuses and overvoltage protection modules, corresponding symbols can be seen in the circuit diagram) within relay box 11, supplying power to components such as compressor 10, condenser fan 1, and solenoid valve 9. The control circuit first performs a self-test (checking voltage stability, sensor initial status, etc.), and enters standby or start-up mode after confirming there are no faults.
[0022] Step 2: The compressor starts, providing cooling power. The control circuit triggers the compressor drive circuit in the relay box 11, causing the compressor 10 to start running. The compressor 10 compresses the low-temperature, low-pressure gaseous refrigerant drawn from the evaporator 8 return port into a high-temperature, high-pressure gaseous refrigerant, which serves as the "power source" for the refrigeration cycle, driving the refrigerant to circulate in the system.
[0023] Step 3: Condensation and Heat Release (Refrigerant changes from gaseous to liquid state). High-temperature, high-pressure gaseous refrigerant enters condenser plate 2, while condenser fan 1 starts, forcing air to flow through the condenser plate fins. The refrigerant releases heat to the air through heat exchange within condenser plate 2, gradually condensing into a medium-temperature, high-pressure liquid refrigerant. A horizontal drying bottle 3 is connected in series in the condensed pipeline to filter moisture and impurities from the refrigerant (preventing expansion valve "ice blockage," compressor corrosion, and other malfunctions).
[0024] Step 4: Throttling and Pressure Reduction (Refrigerant changes from liquid to wet vapor). Medium-temperature, high-pressure liquid refrigerant enters expansion valve 5. Expansion valve 5, through its "throttling effect," causes a rapid drop in refrigerant pressure (from 2 MPa to 0.3 MPa), transforming it into low-temperature, low-pressure wet vapor (a mixture of liquid and gas), preparing for the subsequent "evaporation and heat absorption" process.
[0025] Step 5: Evaporation and Heat Absorption (the refrigerant changes from a liquid to a gaseous state, achieving refrigeration). Low-temperature, low-pressure wet vapor enters the evaporator 8, and the evaporator fan 7 operates, driving air to flow through the evaporator fins. The refrigerant absorbs heat from the air within the evaporator 8, evaporating from a liquid to a gaseous state (completing the core "refrigeration" process); the cooled air is blown out, achieving space cooling. The solenoid valve 9 adjusts the refrigerant flow according to control circuit instructions (e.g., partially closing when the system frequency is reduced to decrease circulation), or cuts off refrigerant flow when the system stops (to prevent compressor "liquid slugging" damage).
[0026] Step Six: Cycle and Intelligent Control. The evaporated, low-temperature, low-pressure gaseous refrigerant is drawn back into the compressor 10, completing the refrigeration cycle of "compression → condensation → throttling → evaporation". The control circuit in the electrical box 6 continuously collects sensor signals (such as evaporator temperature, condensing pressure, ambient temperature, etc., sensor interfaces are visible in the circuit diagram), and achieves intelligent control through logical judgment: if the temperature reaches the set value, the compressor frequency is reduced or stopped, and the fan speed is adjusted; if overpressure, overheating, refrigerant shortage, or other faults are detected, the protection mechanism is triggered (such as voltage fluctuation > ±15%, cutting off the compressor power supply and alarming to prevent damage); the relays in the relay box 11 execute commands in real time, switching the working state of the compressor, fan, and solenoid valve to achieve automatic adjustment. Step Seven: Continuous Protection of Drying and Filtering. The horizontal drying bottle 3 operates continuously during the refrigeration cycle, using a desiccant (such as a molecular sieve) to adsorb moisture in the refrigerant and using a filter to intercept impurities, ensuring the stable operation of precision components such as the expansion valve and compressor, thereby extending the service life of the system.
[0027] The above descriptions are merely embodiments of this utility model, and common technical solutions and / or characteristics known in the scheme are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solution of this utility model. In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances. The scope of protection claimed in this application shall be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.
Claims
1. A top-mounted integrated refrigeration unit, comprising a refrigeration system and an electrical control system, wherein the refrigeration system includes a compressor, a condenser plate, an evaporator, an expansion valve, a condenser fan, an evaporator fan, a solenoid valve, and a horizontal drying flask; the electrical control system includes a power adapter module, a voltage stabilization module, an intelligent protection module, and a relay box, characterized in that: The power adapter module is compatible with 65V-144V DC input; the voltage stabilization module is electrically connected to the power adapter module; the intelligent protection module is electrically connected to the voltage stabilization module and the relay box; the relay box is electrically connected to each component of the refrigeration system.
2. The top-mounted integrated chiller unit according to claim 1, characterized in that: The power adapter module includes a rectifier filter circuit for filtering the input DC power supply, a fuse for overcurrent protection, a TVS diode for overvoltage protection, and an undervoltage protection circuit for cutting off the power supply when the voltage is below 65V.
3. The top-mounted integrated chiller unit according to claim 1, characterized in that: The voltage stabilization module includes a DC-DC regulator and a supercapacitor; the supercapacitor is connected in parallel to the output terminal of the power adapter module to absorb energy during voltage drops.
4. The top-mounted integrated chiller unit according to claim 1, characterized in that: The intelligent protection module includes a microcontroller, a voltage detection circuit, and a soft-start circuit. The microcontroller is used to receive voltage detection signals and output control commands. The voltage detection circuit is used to detect the voltage at the output terminals of the power adapter module and the voltage stabilization module. The soft-start circuit is used to gradually increase the compressor current and decrease the starting current by using a PWM signal when the compressor starts.
5. The top-mounted integrated chiller device according to claim 4, characterized in that: The intelligent protection module also includes a fault alarm unit; when the voltage fluctuation exceeds ±15%, the intelligent protection module cuts off the compressor power supply and records the fault.
6. The top-mounted integrated chiller unit according to claim 1, characterized in that: In the refrigeration system, the compressor's exhaust port is connected to the inlet of the condenser plate, the condenser plate's outlet is connected to the inlet of the horizontal dryer bottle, the horizontal dryer bottle's outlet is connected to the inlet of the expansion valve, the expansion valve's outlet is connected to the inlet of the evaporator, and the evaporator's outlet is connected to the compressor's return port; the condenser fan is located on the air outlet side of the condenser plate, the evaporator fan is located on the air outlet side of the evaporator, and the solenoid valve is located on the pipeline before the expansion valve's inlet.
7. A top-mounted integrated chiller unit according to claim 6, characterized in that: The compressor and condenser are located at one end of the device, and the evaporator is located at the other end of the device. The electrical control system is arranged in the middle area. The condenser has a microchannel parallel flow structure, including multiple layers of aluminum flat tubes and corrugated fins. The drying bottle is installed horizontally and is directly connected between the condenser outlet and the expansion valve inlet to form a low flow resistance channel.
8. The top-mounted integrated chiller unit according to claim 1, characterized in that: The evaporator has a stacked structure, including an evaporation core, a water receiving tray, and a drain pipe; the evaporation core is coated with a hydrophilic coating, and the bottom of the water receiving tray is inclined, with the lowest point connected to the drain pipe.
9. A top-mounted integrated chiller unit according to claim 1, characterized in that: It also includes an integrated housing with an air inlet and an air outlet on the top and a maintenance window on the side; the housing has a partition inside to separate the refrigeration system and the electrical control system into two independent chambers, each with an independent heat dissipation channel; the partition has a sealed wire hole for electrical connection and to prevent refrigerant from leaking into the electrical control chamber.
10. A top-mounted integrated chiller unit according to claim 1, characterized in that: The compressor is a DC inverter scroll compressor.