Vehicular Air Conditioning Case Segmentation for Manufacturing Cost Reduction
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Solution Overview
Problem
Vehicular air conditioning devices face increased manufacturing costs and man-hours due to complex configurations when attempting to share usage of air conditioning case components with varying specifications, particularly in forming seal surfaces and managing air-mix doors for temperature adjustment.
Innovation Solution
The air conditioning case is configured with first and second cases at both ends and a third case in the middle, allowing for a simple partitioning of the upper passage into outer and central openings, and the fitting positions of these cases are arranged such that the upper passage is divided on the inner side, enabling broader opening areas regardless of case size, and allowing for shared usage of mode switching doors by changing the third case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fitting surfaces of case members are assumed to be in a straight line between upper and lower passages to enable shared usage of cases, then case versatility is improved, but passage configuration complexity and manufacturing costs increase
Solution Approach 1:
The air conditioning case is divided into multiple case members (first case member, second case member, third case member) that can be selectively assembled. Each case member is responsible for specific passages (upper passage, lower passage, rear seat passage), allowing flexible configuration depending on the required functionality while maintaining simple individual structures.
Solution Approach 2:
The fitting surfaces of the case members are arranged in a stepped configuration rather than a straight line, creating a tiered structure where the third case member is positioned at a different height level. This dimensional arrangement allows different passage configurations to coexist without requiring complex routing, enabling shared usage of case members across different specifications.
2Ease of operation
If partitioning members are formed in the third case member to divide openings, then air distribution control is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The third case member is divided into multiple partitioning members that separately define different openings (center face opening, side face openings). Each partitioning member can be independently formed and positioned, simplifying the manufacturing process compared to forming complex integrated structures, while still providing precise control over air distribution to different zones.
3Reliability
If seal surfaces are formed around center face openings surrounded by single case members, then sealing ability is improved, but structure complexity and manufacturing costs increase
Solution Approach 1:
A door is introduced as an intermediary component that provides the seal surface for the center face opening. Instead of forming a complex seal structure within the case member itself, the door acts as a movable seal that contacts the case member opening, simplifying the case member structure while ensuring reliable sealing when the door is closed.
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
This configuration simplifies the manufacturing process, reduces costs, and ensures effective sealing and air distribution by maintaining broad opening areas and shared usage of components, thereby reducing manufacturing man-hours and costs.
Implementation Method 1
a heat exchanger in an air conditioning case
Implementation Method 2
a heat exchanger in an air conditioning case
Data Source
AI summary
An air conditioning case configuring a vehicular air conditioning device is configured from first through third case sections capable of being divided in a width direction, the third case section in a center in the width direction and the first case section being connected via a first dividing section, and the third case section and the second case section being connected via a second dividing section. Moreover, the first and second dividing sections are formed in such a manner that their lower section sides facing a lower passage divided in a space between an evaporator and a heating unit are positioned on outer sides in the width direction with respect to an upper section of the air conditioning case provided with a vent blast port blasting air into a vehicle interior.