Compressor Electric-Motor Control Valve for Hysteresis-Free Flow

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Solution Overview

Problem

Existing control valves for air conditioning compressors suffer from imprecise control of refrigerant flow due to mechanical and magnetic interactions, leading to hysteresis and energy inefficiency, particularly in managing the movement of the control piston between positions.

Innovation Solution

A control valve comprising a control piston, an electric motor, and a sensor, where the electric motor precisely moves the control piston between positions using rotational movement translated into translational movement, and a control unit adjusts the refrigerant flow based on the sensor's position determination, eliminating hysteresis and reducing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an electromagnetic annular coil is used to control the control piston, then the control valve can regulate refrigerant flow, but mechanical and magnetic interactions cause hysteresis and imprecise control

Engineering Contradiction:

Improvecontrol precisionVSAvoidenergy inefficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent replaces the electromagnetic annular coil with a linear motor consisting of a stator and translator. This substitution eliminates the magnetic hysteresis and mechanical interactions inherent in electromagnetic coils, providing precise control of the control piston without energy loss to hysteresis effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent incorporates a sensor that detects the position of the control piston and feeds this information back to a control unit. This feedback mechanism enables precise positioning of the control piston by continuously monitoring and adjusting its position based on actual state information.

Inventive Principle:

Principle #23Feedback

2Reliability

If an electromagnetic annular coil is used to hold the control piston in position, then the valve can maintain refrigerant flow control, but constant current flow is required leading to energy consumption

Engineering Contradiction:

Improveposition holding capabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The linear motor replaces the electromagnetic coil's holding function with a mechanical positioning system. The translator can be precisely positioned and held in place without requiring continuous energy input, eliminating the need for constant current flow that characterizes electromagnetic holding systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control system uses periodic positioning commands from the control unit based on feedback from the sensor, rather than continuous energy application. The linear motor receives intermittent activation signals to maintain position, significantly reducing energy consumption compared to continuous electromagnetic field maintenance.

Inventive Principle:

Principle #19Periodic action

3Reliability

If a control piston with seal body is used to block passages, then refrigerant flow can be controlled between areas, but mechanical wear and imprecise positioning occur

Engineering Contradiction:

Improveflow control capabilityVSAvoidpositioning accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The linear motor provides precise electronic positioning of the control piston without mechanical wear. The translator moves along precision-guided rails within the stator, maintaining accurate positioning of the seal body relative to the passages without the degradation associated with traditional mechanical actuation mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables precise control of refrigerant flow with reduced energy consumption by eliminating hysteresis and the need for constant current, improving positioning accuracy and efficiency while minimizing the control valve's size and weight.

Implementation Method 1

an electric motor (202) moving the control piston (204) between the two positions

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a sensor (210) that determines the position of the control piston (204)

Methodology Applied

Scientific EffectPosition sensing:

Data Source

PatentUS10451048B2Electrical control valve for an air conditioning compressor

Publication Date: 2019.10.22 TE CONNECTIVITY GERMANY GMBH

AI summary

A control valve for an air conditioning compressor is disclosed. The control valve comprises a control piston, an electric motor, a sensor, and a control unit. The control piston connects a refrigerant flow between a high-pressure area and a crankcase pressure area of the air conditioning compressor in a first position. The control piston further connects the refrigerant flow between the crankcase pressure area and a low-pressure area of the air conditioning compressor in a second position. The electric motor moves the control piston between the first position and the second position. The sensor determines the position of the control piston. The control unit is connected to the sensor and the electric motor. The control unit controls the electric motor to move the control piston and control the refrigerant flow based on the position of the control piston determined by the sensor.