Air Conditioner Power Module Current Control for Burn-Out Prevention
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Solution Overview
Problem
Inverter-type air conditioners face a risk of power module burn-out due to high temperatures, particularly when outdoor air temperatures increase, as power modules are more susceptible to heat and have a higher risk of damage.
Innovation Solution
An air conditioner system that includes a power module temperature sensor and processor to detect and adjust the current applied to the compressor based on the power module's temperature, limiting or increasing the current according to outside air temperature and power module conditions to prevent overheating and enhance cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the current to the compressor is increased to improve cooling performance, then the cooling capacity is improved, but the power module temperature increases leading to burn-out risk
Solution Approach 1:
The patent implements dynamic current adjustment by continuously monitoring power module temperature and modifying compressor current in real-time based on temperature thresholds. The control system dynamically increases current when temperature is below the reference threshold and decreases current when temperature exceeds the threshold, allowing the system to adapt to changing thermal conditions and maintain optimal performance while preventing overheating.
Solution Approach 2:
The patent employs a feedback control mechanism where the power module temperature sensor continuously monitors temperature and feeds this information back to the control system. The control system processes this feedback and adjusts the compressor current accordingly, creating a closed-loop control system that automatically maintains the power module temperature within safe operating limits while maximizing cooling capacity.
2Reliability
If the current to the compressor is limited to prevent power module overheating, then the power module reliability is improved, but the cooling performance deteriorates
Solution Approach 1:
The system dynamically adjusts current limits based on real-time temperature measurements rather than applying a fixed current limit. When the power module temperature is below the reference threshold, the system allows current up to the upper limit current for maximum cooling performance. When temperature exceeds the threshold, the system dynamically reduces the current limit to prevent overheating, thus maintaining reliability without unnecessary performance loss.
Solution Approach 2:
The patent changes the operating parameters (current magnitude) based on the thermal state of the power module. By monitoring temperature and adjusting current as a variable parameter, the system optimizes the balance between cooling capacity and power module reliability, allowing high current operation when thermal conditions permit and reducing current only when necessary to prevent overheating.
3Productivity
If the upper limit current is set high to maintain cooling performance, then the cooling capacity is maintained, but the power module is more susceptible to heat damage
Solution Approach 1:
The patent implements preliminary protective action by continuously monitoring power module temperature and taking preventive measures before thermal damage occurs. The control system detects temperature trends and reduces current before the power module reaches dangerous temperature levels, preventing heat damage while maintaining cooling performance during normal operation.
Solution Approach 2:
The patent converts the potentially harmful effect of high current (which causes both desired cooling and harmful heat generation) into a beneficial controlled process. By using temperature feedback to modulate current, the system harnesses the cooling effect of high current operation while preventing the harmful thermal accumulation, effectively separating the beneficial and harmful aspects of high current operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively prevents power module burn-out by dynamically adjusting the current based on temperature, ensuring efficient cooling performance even at high outdoor temperatures.
Implementation Method 1
a power module temperature sensor configured to detect a temperature of the power module
Implementation Method 2
The air conditioning system may control a compressor therein to compress a refrigerant at a high temperature and high pressure
Implementation Method 3
The refrigerant compressed at the high temperature and high pressure circulates through a refrigeration cycle within the air conditioning system and absorbs heat via a heat exchanger located in an indoor unit, thereby cooling the air around the heat exchanger
Data Source
AI summary
An air conditioner is provided. The air conditioner includes a compressor, a power module configured to drive the compressor, a power module temperature sensor configured to detect a temperature of the power module, memory storing one or more computer programs, and one or more processors communicatively coupled to the compressor, the power module, the power module temperature sensor, and the memory, wherein the one or more computer programs include computer-executable instructions that, when executed by the one or more processors individually or collectively, cause the air conditioner to determine whether a current of the compressor corresponding to a target frequency of the compressor is greater than or equal to an upper limit current corresponding to an outside air temperature, and based on determining that the current of the compressor is greater than or equal to the upper limit current corresponding to the outside air temperature, when the outside air temperature is lower than a reference temperature, limit a current being applied to the compressor to less than the upper limit current corresponding to the outside air temperature, and when the outside air temperature is higher than or equal to the reference temperature, increase the current being applied to the compressor to greater than or equal to the upper limit current based on the detected temperature of the power module.