Electric Machine Mechanical Coupling for HVAC Compressor
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Solution Overview
Problem
Hybrid and electric vehicles face high fuel consumption and inefficient heating of interiors due to insufficient waste heat from electric machines, requiring additional complex and expensive electric resistance heaters, and additional electric motors for air conditioning, which increases assembly effort and weight.
Innovation Solution
A drive train system where the electric machine is mechanically coupled to the air-conditioning compressor, combined with power electronics in a modular unit, using a hydraulic cooling circuit to dissipate waste heat, allowing the electric machine to drive the air-conditioning compressor and heat the interior without additional motors or heaters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an additional electric resistance heater is used to heat the interior when the electric machine operates as an electric motor, then the interior heating function is achieved, but the device complexity and cost increase
Solution Approach 1:
The electric machine is designed to perform multiple functions: it serves as both the traction motor for vehicle propulsion and as a generator for waste heat recovery. By integrating the heating function into the electric machine's operational byproducts, the patent eliminates the need for separate heating components like PTC heaters, thereby reducing device complexity while maintaining interior heating capability
Solution Approach 2:
The patent converts the waste heat that would otherwise be discarded during electric motor operation into a useful heating resource for the vehicle interior. The thermal energy that is normally lost is now captured through the cooling circuit and redirected to heat the interior, transforming a harmful waste product into a beneficial resource
2Ease of manufacture
If separate modular units with separate housings are used for the electric machine and power electronics, then the manufacturing and maintenance become easier, but the assembly effort and number of parts increase
Solution Approach 1:
The patent integrates the power electronics directly into the electric machine housing, creating a unified modular unit. This merging of previously separate components (electric machine and power electronics) into a single integrated assembly reduces the total number of parts, simplifies assembly procedures, and decreases the number of electrical connections required, while maintaining the functional independence and manufacturability of the combined unit
3Ease of operation
If a separate electric motor is used to drive the mechanical air-conditioning compressor, then the air conditioning function is achieved, but the weight and device complexity increase
Solution Approach 1:
The electric machine serves dual purposes: providing mechanical energy for vehicle propulsion and driving the air-conditioning compressor through mechanical coupling. This multi-functionality eliminates the need for a dedicated compressor motor, reducing the overall weight of the drive train while ensuring the air conditioning system remains fully operational
4Weight of moving object
If the electric machine is used to mechanically drive the air-conditioning compressor, then the weight and cost are reduced, but the mechanical coupling complexity increases
Solution Approach 1:
The air-conditioning compressor is integrated directly into the electric machine housing, with the compressor shaft mechanically coupled to the electric machine rotor. This merging of the compressor into the existing electric machine structure utilizes the same rotational motion for dual purposes, avoiding the need for separate mounting brackets, belts, or additional mechanical transmission components
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 solution reduces the need for additional electric motors and heaters, lowers costs, and optimizes energy efficiency by utilizing waste heat for interior heating and cooling, while simplifying assembly and reducing weight.
Implementation Method 1
an electric machine for the driving or traction of the vehicle... converting electrical energy to mechanical energy
Implementation Method 2
the evaporator of the refrigeration circuit is connected thermally to the power electronics in order to carry waste heat from the power electronics to the evaporator and cool the power electronics by means of the evaporator
Implementation Method 3
an electric-machine heat exchanger for transferring heat from the electric machine to the cooling fluid
Implementation Method 4
an ambient-heat heat exchanger for transferring heat from the cooling fluid to the ambient air
Implementation Method 5
a circulating pump, an electric-machine heat exchanger for transferring heat from the electric machine to the cooling fluid
Data Source
AI summary
The invention relates to a drive train (1), in particular for a vehicle as an electric vehicle or hybrid vehicle, comprising: an electric machine (6) for the driving or the traction of the vehicle (2); a refrigeration circuit (14), which has an air-conditioning compressor (19), an evaporator (17), a condenser (18), and an expansion valve (16), for cooling an interior (5) of the vehicle (2); and a drive unit for mechanically driving the air-conditioning compressor (19), wherein the electric machine (6) is mechanically coupled to the air-conditioning compressor (19) by means of a mechanical compressor coupling element (20) such that the electric machine (19) for the driving or the traction of the vehicle (2) is used additionally to mechanically drive the air-conditioning compressor (19).