Air Management System Reducing Compressor Startup Torque
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Solution Overview
Problem
Air management systems for automotive vehicles face issues with compressor motor stalling due to increased torque requirements when starting, leading to undesirable effects like blown fuses and noticeable noise from manifold exhaust.
Innovation Solution
An air management system with a compressor, reservoir tank, manifold block, valves, pressure sensors, and an electronic control unit that selectively connects the reservoir tank to the compressor inlet using a boost valve, allowing pressurized air to be provided without exhausting the manifold, thereby reducing startup torque and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the manifold is exhausted to reduce pressure before starting the compressor, then the compressor motor can start without stalling, but noticeable noise is produced from the rushing air
Solution Approach 1:
A reservoir tank is introduced as an intermediary component between the manifold and the compressor inlet. The reservoir tank receives pressurized air from the manifold and delivers it to the compressor inlet, allowing the compressor to receive pressurized air without requiring the manifold to be exhausted, thus eliminating the noise while ensuring reliable compressor startup
Solution Approach 2:
The reservoir tank is pre-filled with pressurized air from the manifold before the compressor needs to start. This preliminary action ensures that when the compressor requires air, pressurized air is already available in the reservoir tank, eliminating the need to exhaust the manifold and preventing both noise and compressor stalling
2Object-affected harmful factors
If pressurized air is provided to the compressor inlet without exhausting the manifold, then noise is eliminated, but the compressor motor may stall due to increased startup torque
Solution Approach 1:
The reservoir tank acts as a buffer between the manifold and compressor, storing pressurized air and delivering it to the compressor inlet. This allows the compressor to receive pressurized air without creating a large pressure difference at the manifold, reducing startup torque while eliminating exhaust noise
Solution Approach 2:
The system changes the pressure parameters by introducing a reservoir tank that maintains a intermediate pressure level. The reservoir tank receives high pressure from the manifold and delivers controlled pressure to the compressor inlet, modifying the pressure transition to reduce startup torque requirements
3Loss of energy
If the manifold pressure is maintained without exhausting it, then air pressure is conserved, but the compressor requires increased torque to start
Solution Approach 1:
The reservoir tank serves as an intermediary that decouples the manifold pressure from the compressor inlet pressure. It allows the manifold to maintain its pressure (conserving air) while the reservoir tank provides the necessary pressurized air to the compressor through controlled delivery, reducing the torque requirement
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 reduces startup torque and eliminates noise associated with manifold exhaust, preventing compressor motor stalling and conserving air pressure within the manifold.
Implementation Method 1
A boost valve is coupled to the reservoir tank for selectively directly connecting the reservoir tank and an inlet of the compressor
Implementation Method 2
start a motor of said compressor while retaining pressure in said manifold block
Implementation Method 3
A compressor for providing pressurized air
Implementation Method 4
At least one pressure sensor is coupled to the manifold block for determining the pressure in the manifold block
Data Source
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AI summary
An air management system (20) and method are provided. The system includes a compressor (26) and a reservoir tank (50) coupled to the compressor. A manifold block (28) has a plurality of valves (36) and is coupled to the reservoir tank and the compressor for controlling air flow. At least one pressure sensor (54) is coupled to the manifold block. The compressor includes a boost valve (38) for selectively directly connecting the reservoir tank and an air inlet of the compressor. An electronic control unit (56) is coupled to the valves, compressor, and the at least one pressure sensor and is configured to provide pressurized air from the reservoir tank to the air inlet, determine a pressure difference between the manifold block and the boost valve, and retain pressure in the manifold block in response to the pressure difference being less than a predetermined amount to reduce startup torque of the compressor without exhausting the manifold block.