Dual Compressor Climate Control With Dynamic Speed Separation
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Solution Overview
Problem
Dual compressor automotive climate systems often produce a beating or heterodyne noise when both compressors operate at similar speeds, which can be disturbing for vehicle occupants, especially in harsh conditions requiring dual cooling for batteries and cabins.
Innovation Solution
Implementing a controller that dynamically adjusts the speed of the secondary compressor by setting a minimum and maximum threshold based on the primary compressor's speed, ensuring a fixed speed separation throughout all operating conditions, thereby preventing noise issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If both compressors operate at similar speeds to provide cooling for battery and cabin, then cooling performance is improved, but beating or heterodyne noise is generated
Solution Approach 1:
The patent implements dynamic speed control where the controller continuously adjusts the speed of the second compressor based on the real-time speed of the first compressor. The controller maintains a speed separation by preventing the second compressor speed from falling below a minimum threshold (when first compressor speed is low) or exceeding a maximum threshold (when first compressor speed is high), thereby dynamically eliminating the beating noise while preserving cooling effectiveness
Solution Approach 2:
The patent changes the operating parameter (speed) of the second compressor to resolve the contradiction. By establishing minimum and maximum speed thresholds for the second compressor relative to the first compressor's speed, the system modifies the speed parameter to prevent frequency alignment that causes beating noise, while still maintaining adequate cooling performance through the second compressor's operation within the threshold range
2Object-affected harmful factors
If compressor speeds are separated to prevent noise, then noise is reduced, but cooling performance may be compromised
Solution Approach 1:
The controller implements feedback control by continuously monitoring the speed of the first compressor and using this information to adjust the speed of the second compressor. The controller receives feedback about the first compressor's operating state and dynamically modifies the second compressor's speed to maintain the threshold separation, ensuring noise reduction while preserving cooling effectiveness through closed-loop control
Solution Approach 2:
The patent applies partial action by not completely disabling the second compressor when speed separation is needed. Instead of turning off the second compressor entirely to eliminate noise, the system maintains it at a reduced but still effective speed within the threshold range, providing sufficient cooling performance while achieving noise reduction through partial operation
Data Source
AI summary
While a speed of a first compressor during operation is less than a threshold speed, a speed of a second compressor during operation is prevented from falling below a minimum threshold speed that is defined by a sum of the speed of the first compressor and a predefined offset speed delta such that the minimum threshold speed changes as the speed of the first compressor changes.