Electric Compressor Housing With Integrated Refrigerant Sensors
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Solution Overview
Problem
Existing electric compressors in battery-powered vehicles require direct measurement of refrigerant pressure and temperature for efficient operation, but external sensors introduce additional costs and complexity, and there is a need for integrated sensors to optimize decision-making and reduce battery drain.
Innovation Solution
The electric compressor integrates pressure and temperature sensors within the compressor housing, allowing direct measurement of refrigerant conditions and enabling optimized control without external sensors, thus reducing complexity and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are used to measure refrigerant pressure and temperature, then measurement capability is provided, but device complexity and cost increase due to additional sensors and wiring
Solution Approach 1:
The patent merges the pressure sensor and temperature sensor directly into the compressor housing structure. The pressure sensor is integrated into the discharge port area, while the temperature sensor is embedded in the housing near the compression chamber, eliminating the need for separate external sensor installations and reducing wiring complexity.
Solution Approach 2:
The compressor housing is designed to serve multiple functions: it not only contains the compression mechanism but also integrates sensor mounting capabilities, structural support, and thermal management functions. This multi-functionality reduces the need for separate components and simplifies the overall system architecture.
2Loss of information
If external sensors are used for refrigerant measurement, then pressure and temperature data are obtained, but energy consumption increases due to additional power requirements
Solution Approach 1:
The integrated sensors are designed to be powered directly by the compressor's internal electrical system, utilizing the same power source that drives the compression motor. This self-service approach eliminates the need for separate power supplies and reduces overall energy consumption by sharing the existing electrical infrastructure.
3Measurement precision
If external sensors are installed in refrigerant lines, then pressure and temperature can be measured, but manufacturing cost and installation labor increase
Solution Approach 1:
The pressure sensor and temperature sensor are merged into the compressor housing as integral components. The pressure sensor is positioned at the discharge port, and the temperature sensor is embedded in the housing wall near the compression chamber, allowing both sensors to be installed during compressor manufacturing rather than requiring separate field installations.
4Ease of manufacture
If sensors are positioned far from the compression chamber, then sensor installation is simplified, but measurement accuracy decreases due to pressure and temperature disturbances in refrigerant lines
Solution Approach 1:
The sensors are positioned at specific locations within the compressor housing where local conditions provide accurate measurements. The pressure sensor is placed at the discharge port where pressure is stable, and the temperature sensor is embedded in the housing wall adjacent to the compression chamber where refrigerant temperature is representative of the compression process, ensuring high measurement accuracy without requiring distant sensor placement.
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 integrated sensors enhance operational efficiency, reduce noise, and extend the operating life of the compressor by optimizing power usage and eliminating the need for external sensors and additional wiring.
Implementation Method 1
The pressure sensor is positioned within the inverter cavity adjacent the inverter cavity end of the passage for sensing a pressure associated with the refrigerant within the passage
Implementation Method 2
The inverter module is mounted inside the inverter cavity of the housing and is adapted to convert direct current electrical power to alternating current electrical power
Implementation Method 3
The motor is mounted inside the housing. The compression device is coupled to the motor, receives the refrigerant from the intake volume and compresses the refrigerant as the motor is rotated
Implementation Method 4
The compression device is coupled to the motor, receives the refrigerant from the intake volume and compresses the refrigerant as the motor is rotated
Data Source
AI summary
An electric compressor includes a housing, refrigerant inlet port, a refrigerant outlet port, an inverter section, a motor section, a compression device and a front cover. The housing defines an intake volume and a discharge volume. The refrigerant inlet port is coupled to the housing and is configured to introduce the refrigerant to the intake volume. The compression device is a scroll-type compression device configured to compress the refrigerant. The refrigerant outlet port is coupled to the housing and is configured to allow compressed refrigerant to exit the scroll-type electric compressor from the discharge volume. The electric compressor includes integral pressure(s) and/or temperatures sensor(s).