Outdoor Control Unit Modular Layout for Multi-Air Conditioners
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Solution Overview
Problem
Conventional air conditioners have complex and unreliable control units due to linear transformer design, leading to increased electromagnetic interference and difficulty in modifying control variables.
Innovation Solution
The control unit for the outdoor unit is divided into multiple blocks, including a power factor compensation circuit, compressor inverter, fan motor inverters, system controller, and noise filter, each mounted on separate substrates, simplifying wiring and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power modules are designed as linear transformers, then the control unit can be compact, but the interconnection between power modules becomes very complicated
Solution Approach 1:
The control unit is divided into separate power modules (first power module, second power module, third power module) mounted on different substrates. Each module handles specific functions (compressor control, fan control, heat exchanger control), allowing independent design and simplifying interconnections through standardized interfaces rather than complex linear transformer wiring.
2Device complexity
If power modules are designed as linear transformers, then the control unit structure is simple, but the reliability of the control unit deteriorates
Solution Approach 1:
By segmenting the control unit into separate power modules mounted on different substrates, the system achieves both structural simplicity and improved reliability. Each module can be independently tested, replaced, or maintained without affecting other modules, thereby enhancing overall system reliability while maintaining design simplicity.
3Ease of manufacture
If power modules are designed as linear transformers, then the control unit design is straightforward, but additional cost for handling electromagnetic interference is incurred
Solution Approach 1:
The patent introduces separate substrates as intermediary platforms for mounting power modules. These substrates act as physical and electromagnetic isolators between different power modules, reducing electromagnetic interference while maintaining straightforward design and assembly processes. The modular substrate-based architecture simplifies EMI management compared to integrated linear transformer designs.
4Device complexity
If power modules are designed as linear transformers, then the control unit structure is conventional, but it becomes difficult to alter control variables
Solution Approach 1:
The segmented modular architecture with separate substrates enables independent modification of each power module's control parameters and characteristics. Engineers can alter control variables in individual modules without redesigning the entire control unit, providing flexibility and adaptability while maintaining overall structural simplicity.
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 configuration improves signal transmission efficiency, reduces noise and resistance, and facilitates easier modification of control variables, enhancing the overall operating efficiency and user convenience of the control unit.
Implementation Method 1
The control unit includes a power factor compensation (PFC) circuit which converts alternating current (AC) power provided by a commercial AC power source into direct current (DC) power
Implementation Method 2
a compressor inverter which drives a compressor motor by converting the DC power into AC power
Implementation Method 3
a fourth block having a filter for removing noise from input three-phase power
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
An air conditioner is provided. A control unit of an outdoor unit of the air conditioner is divided into a plurality of blocks according to a set of rules. Then, the blocks are mounted on different substrates. Therefore, it is possible to simplify wiring, facilitating the interconnection of the blocks and enable the control unit to be managed in units of the blocks. In addition, it is possible to improve user convenience.