Multi-zone HVAC Split-flow Module for Automotive Energy Efficiency
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Solution Overview
Problem
Multi-zone HVAC systems in automotive vehicles consume excessive energy when operating at maximum power to supply varying airflow requests across zones, necessitating a more efficient energy-saving solution.
Innovation Solution
A split-flow design for the HVAC module, where the air inlet is divided into outside air (OSA) and recycled air (REC) portions, with temperature doors controlling the flow of these streams to optimize airflow distribution across different zones, including a separation valve to separate or combine OSA and REC streams for heating and cooling modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fan of the high performance HVAC unit is run at maximum power to supply all zone outlets with sufficient air flow, then all zone outlets receive sufficient air flow for any operator-requested settings, but the HVAC control consumes an undesirably high amount of energy
Solution Approach 1:
The air inlet is divided into two separate inlets: a first inlet for outside air and a second inlet for recycled air. The housing is segmented into a first volume receiving outside air and a second volume receiving recycled air. This segmentation allows independent control of air streams, enabling the system to optimize energy consumption by selectively processing only the necessary air volumes through the evaporator and heater, rather than circulating all air at maximum capacity.
Solution Approach 2:
The system changes the operational parameters by introducing separate control pathways for outside air and recycled air. Temperature doors independently regulate the mixing ratios and flow rates of these two air streams. This parameter control enables the HVAC system to operate at variable loads rather than fixed maximum capacity, significantly reducing energy consumption while maintaining adequate air flow to all zones.
2Use of energy by moving object
If separate inlets and volumes are introduced for outside air and recycled air, then energy consumption is reduced through selective air processing, but the device complexity increases
Solution Approach 1:
The housing is segmented into distinct volumes for outside air and recycled air, with separate inlet paths. While this creates structural complexity, the segmentation is achieved through straightforward spatial division rather than complex mechanical components. The temperature doors serve dual functions by simultaneously controlling multiple air streams, which helps offset the added structural complexity.
Solution Approach 2:
The temperature doors are designed with multi-functionality, serving as universal control elements that regulate both outside air and recycled air streams. Each temperature door controls multiple airflow paths and mixing ratios, allowing a single component to perform several control functions. This multi-functionality reduces the total number of separate control mechanisms needed, thereby mitigating the increase in device complexity.
3Ease of operation
If temperature doors control multiple air streams and mixing ratios, then precise temperature and airflow adjustments are achieved across zones, but the control mechanism complexity increases
Solution Approach 1:
Each temperature door is designed as a universal control element that simultaneously manages multiple air streams (outside air and recycled air) and controls mixing ratios for different zone outlets. This multi-functionality allows precise temperature and airflow adjustment across all zones using a minimized set of control mechanisms, rather than requiring separate controls for each air stream and outlet.
Solution Approach 2:
The control functions for multiple air streams and mixing ratios are merged into the temperature door mechanisms. Rather than having separate controls for outside air flow, recycled air flow, and mixing ratios, the temperature doors integrate these control functions into single adjustable components. This merging simplifies the overall control mechanism while maintaining precise adjustment capabilities.
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 design achieves a 30% reduction in heating load and allows for precise temperature and airflow adjustments across zones, enhancing energy efficiency and comfort by optimizing the use of outside and recycled air.
Implementation Method 1
an evaporator and a heater downstream of the evaporator are disposed in the housing
Implementation Method 2
an evaporator and a heater downstream of the evaporator are disposed in the housing
Data Source
AI summary
An HVAC module for an automotive vehicle includes a housing defining an air inlet, an upper front zone outlet, a lower front zone outlet, and a rear zone air outlet. An evaporator and a heater downstream of the evaporator are disposed in the housing. The air inlet of the housing is divided by a first divider into an OSA portion exclusively receiving outside air and a REC portion exclusively receiving recycled air. Each of the evaporator and the heater has a respective OSA portion receiving the outside air and a REC portion receiving the recycled air entering the HVAC module through the inlet. A second divider between the evaporator and the heater directs the outside air from the REC portion of the evaporator to the REC portion of the heater. Two temperature doors control access of separate partial streams of the recycled air from the evaporator to the heater.