Modular EV Air Conditioning with Segmented Heat Pump Control
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Solution Overview
Problem
Existing air conditioning systems for electric vehicles face challenges in providing efficient heating and cooling due to the lack of waste heat from internal combustion engines, and they often suffer from technical defects, long and costly high-pressure cooling lines, increased susceptibility to leaks, and inflexible regulation of heating or cooling capacity.
Innovation Solution
A modular air conditioning device with multiple refrigerant circuits, each comprising a compressor, heat exchangers, and a valve device, controlled by a central unit to switch between cooling and heating modes, allowing for flexible operation and adaptation to changing conditions, including de-icing and partial load operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a single air conditioning system is used in electric vehicles, then the system structure is simple, but the heating efficiency is insufficient due to lack of waste heat from internal combustion engines
Solution Approach 1:
The air conditioning system is divided into multiple independent air conditioning modules, each capable of independent operation. This segmentation allows the system to achieve heat pump functionality for improved heating efficiency while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
Each air conditioning module is designed as a multi-functional unit that can operate in both cooling mode and heating mode (heat pump function). This universality eliminates the need for separate heating and cooling systems, improving overall energy efficiency while avoiding excessive system complexity.
2Reliability
If multiple air conditioning modules are used, then the reliability increases and flexible capacity regulation is enabled, but the device complexity increases
Solution Approach 1:
The system uses multiple independent air conditioning modules with identical or similar structures. This segmentation approach increases reliability through redundancy while keeping individual module complexity low, as each module is a standardized unit.
Solution Approach 2:
The central control device regulates the operating parameters (such as compressor speed, valve positions, and heat exchanger configuration) of each module to optimize system performance. By dynamically adjusting parameters rather than adding complex hardware, the system achieves flexible capacity regulation without proportionally increasing device complexity.
3Use of energy by moving object
If heat pump system is used for heating, then the energy efficiency is improved, but the susceptibility to icing increases
Solution Approach 1:
The system converts the harmful icing condition into a beneficial heating opportunity. When icing is detected on the outdoor heat exchanger of one module, the central control device switches that module to heating mode, where the outdoor heat exchanger functions as a condenser. The module then provides heating capacity while its heat exchanger serves as a de-icing source, converting the icing harm into useful heating energy.
Solution Approach 2:
The central control device continuously monitors the operating status of each air conditioning module, including temperature and icing conditions. Based on this feedback, the control device dynamically adjusts the operating mode of each module, switching between cooling and heating modes to prevent icing while maintaining energy efficiency.
4Power
If the outdoor heat exchanger is used for heat exchange in heating mode, then the heating capacity is provided, but the icing of the heat exchanger occurs under certain air conditions
Solution Approach 1:
The system implements periodic switching between cooling and heating modes for the outdoor heat exchanger. When icing conditions are detected, the heat exchanger periodically switches to heating mode to melt the ice, then returns to cooling mode to restore heating capacity. This periodic action prevents permanent icing damage while maintaining reliable heating performance.
Solution Approach 2:
The system segments the heating function across multiple air conditioning modules. When one module's outdoor heat exchanger is iced, other modules can continue providing heating capacity. This segmentation ensures that the overall system heating capacity is maintained even when individual heat exchangers experience icing.
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 system ensures reliable and flexible air conditioning with adaptable heating and cooling capacity, minimizing the impact of module failures and optimizing energy use, while reducing the risk of icing and evenly distributing the workload among modules for extended service life.
Implementation Method 1
a first heat exchanger (W1) for exchanging heat with a vehicle exterior and/or a component of an electric drive
Implementation Method 2
a second heat exchanger (W2) for exchanging heat with a vehicle interior and/or a component of an electric drive
Implementation Method 3
Each of the refrigerant circuits includes a compressor (3)
Implementation Method 4
a first throttle device (4a)
Data Source
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Figure 3
AI summary
The invention relates to a modular air conditioning device 100 for a motor vehicle, a motor vehicle with a corresponding modular air conditioning device 100, and a method for pre-configuring such a modular air conditioning device 100. The air conditioning device 100 comprises at least two air conditioning modules 10a, 10b, 10c, each of which includes a refrigerant circuit 1a, 1b, 1c with a compressor, a first heat exchanger, a second heat exchanger, a first throttling device, and a valve device for controlling the refrigerant flow within the refrigerant circuit 1a, 1b, 1c. By controlling the refrigerant flow, the refrigerant circuits 1a, 1b, 1c can each be operated in a first operating mode M1 as a refrigeration machine and in a second operating mode M2 as a heat pump.Furthermore, the air conditioning device 100 comprises a central control unit 20, which is configured to determine a number of active air conditioning modules 10a, 10b, 10c depending on at least one monitored operating condition and/or to determine whether an active air conditioning module 10a, 10b, 10c is operated in the first or second operating mode M1 or M2.