Modular Electric Refrigerant Drive Segmentation
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Solution Overview
Problem
Existing refrigerant compressors for air conditioning systems in motor vehicles lack flexibility in accommodating different refrigerants, leading to increased manufacturing and assembly costs and reduced adaptability.
Innovation Solution
A modular electric refrigerant drive comprising a drive module and a compressor module, allowing for separate production and coupling, with a brushless electric motor and motor electronics, and a scroll compressor design that enables flexible adaptation to various refrigerants by using different voltage levels and refrigerant types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a shared one-piece housing is used for the electric motor and compressor, then structural simplicity is achieved, but flexibility for different refrigerants and manufacturing adaptability are reduced
Solution Approach 1:
The housing is divided into a motor housing for the electric motor and a compressor housing for the compressor, allowing independent manufacturing and assembly. This segmentation enables the compressor module to be adapted for different refrigerants while keeping the motor module standardized, thus improving flexibility without significantly increasing overall structural complexity.
2Adaptability or versatility
If the electric motor and compressor are manufactured separately and then coupled, then flexibility and pre-testing capability are improved, but assembly complexity increases
Solution Approach 1:
The drive module and compressor module are manufactured separately as independent units, enabling pre-testing of the drive module before final assembly. This segmentation allows for modular replacement and adaptation to different refrigerant requirements while maintaining manageable assembly complexity through standardized coupling interfaces.
3Ease of manufacture
If a shared housing is used, then manufacturing cost is reduced, but production flexibility and quality control are worsened
Solution Approach 1:
By segmenting the housing into separate motor and compressor portions, each module can be manufactured using optimized processes for its specific requirements. The compressor module can be produced with high precision for specific refrigerant applications while the motor module uses standardized manufacturing, achieving cost efficiency through volume production of standardized components while maintaining flexibility for specialized modules.
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 modular design reduces production and assembly costs, enhances flexibility, and improves reliability by allowing pre-testing of the drive module independently, while minimizing leaks and noise through a secure and efficient propulsive coupling and lubrication system.
Implementation Method 1
an electric motor drive (4, 12, 20) with a brushless electric motor (20)
Implementation Method 2
the two scroll parts in this case are typically designed as a nested (helical) spiral or scroll pair... each orbiting motion between the spirals forms two substantially crescent-shaped (refrigerant) chambers, which is increasingly reduced in volume (compressed) during movement
Implementation Method 3
minimizing leaks and noise through a secure and efficient propulsive coupling and lubrication system
Data Source
AI summary
An electric refrigerant drive, in particular a refrigerant compressor for an air conditioner of a motor vehicle, has an electric motor drive module and a compressor module coupled to the drive module. The drive module has a motor housing which houses an electric motor with a rotatable motor shaft and is joined to an end shield. The drive module also comprises a fluid-tight housing partition opposite the end shield, thereby forming an electronic housing that receives an electronic motor unit and is closed by a housing cover. The compressor module has a compressor housing which is attached to the end shield of the motor housing of the drive module and which receives a compressor part that is coupled or can be coupled to the drive module so as to be driven.