AC Drive Thermal Control via Inverter Switching Frequency Reduction

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Air conditioning systems with electrically driven components often shut down unnecessarily due to temperature thresholds exceeded by power switching devices, leading to inefficiencies and operational disruptions.

Innovation Solution

An air conditioning system with a controller that monitors temperature and reduces the switching frequency of power switching devices in the converter and inverter by adjusting the carrier signal period and using hybrid pulse width modulation (HPWM) control, and further reduces compressor load by adjusting refrigerant flow or speed when temperatures remain high.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the air conditioning system shuts down when temperature exceeds threshold, then power switching devices are protected from damage, but system operational continuity deteriorates

Engineering Contradiction:
Improvepower switching device protectionVSAvoidsystem operational continuity
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent applies dynamics by transitioning from a static shutdown threshold to a dynamic temperature management approach. The controller continuously adjusts the switching frequency based on real-time temperature monitoring, allowing the system to adapt its operation to prevent overheating while maintaining continuous operation. This dynamic adjustment resolves the contradiction by protecting devices through active management rather than passive shutdown.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the operating parameter of switching frequency in response to temperature conditions. When temperature exceeds the threshold, the controller reduces the switching frequency rather than shutting down the system. This parameter change allows the system to maintain operation at reduced capacity, protecting power switching devices from thermal damage while avoiding complete operational interruption.

Inventive Principle:
Principle #35Parameter changes

2Temperature

If the switching frequency is reduced to lower temperature, then power switching device temperature decreases, but system efficiency deteriorates

Engineering Contradiction:
Improvepower switching device temperatureVSAvoidsystem efficiency
Core Design Contradiction:
TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent applies partial action by reducing the switching frequency only to the extent necessary to control temperature, rather than uniformly reducing all system operations. The controller monitors temperature and adjusts switching frequency proportionally, maintaining optimal efficiency at normal temperatures and applying frequency reduction only when and to the degree that temperature control is required.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The patent implements feedback control where the controller continuously monitors the temperature of power switching devices and uses this information to adjust the switching frequency. This closed-loop feedback system ensures that frequency reduction is applied only when temperature exceeds thresholds, automatically restoring normal frequency when temperatures are acceptable, thereby minimizing efficiency loss while achieving temperature control.

Inventive Principle:
Principle #23Feedback

3Temperature

If the carrier signal period is increased to reduce switching frequency, then power switching device temperature is controlled, but control signal complexity increases

Engineering Contradiction:
Improvepower switching device temperatureVSAvoidcontrol signal configuration
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent applies self-service by implementing automatic carrier signal period adjustment through the controller. Rather than requiring manual configuration of control signal parameters, the system autonomously monitors temperature and dynamically adjusts the carrier signal period to achieve appropriate switching frequency reduction. This self-adjusting mechanism simplifies operation while maintaining temperature control capability.

Inventive Principle:
Principle #25Self-service

Data Source

PatentEP4231511A1Thermal regulation of drive in air conditioning systems
Publication Date: 2023.08.23 CARRIER CORP
  • EP4231511A1 patent drawingFigure 1
  • EP4231511A1 patent drawingFigure 2
  • EP4231511A1 patent drawing

AI summary

An air conditioning system (100) includes a compressor (104) including a motor (102), a condenser (106), and an evaporator (108); a drive (101) including converter (200) and an inverter (110), the converter (200) and the inverter (110) including power switching devices (211); a temperature sensor (402) configured to sense a temperature in at least one of the converter (200) and the inverter (110); a controller (340) configured to communicate with the temperature sensor (402), the controller (340) configured to provide a control signal to the inverter (110), the controller (340) configured to execute: monitor the temperature; compare the temperature to a threshold; when the temperature exceeds the threshold, executing an operation to reduce a switching frequency of the power switching devices (211) in the inverter (110).