Pilot-Controlled Capacity Valve for High-Flow Compact Compressors
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Solution Overview
Problem
Existing capacity control valves for variable displacement compressors in air conditioning systems face challenges in achieving high energy efficiency while maintaining a compact size, as they require larger solenoids and valve openings to increase refrigerant flow rate, leading to deteriorated energy efficiency and size constraints.
Innovation Solution
A capacity control valve design incorporating a CS valve with a biasing member and a pilot valve driven by a solenoid, which reduces the driving electric power and increases the valve opening degree, allowing for adjustable pressure and flow rate control, and a compact configuration using a hollow cylindrical CS valve body and pilot valve seat with an orifice for fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the solenoid size and valve opening diameter are enlarged to increase refrigerant flow rate, then the flow rate control capability is improved, but the energy efficiency deteriorates and the device size increases
Solution Approach 1:
A pilot valve is introduced as an intermediary component between the solenoid and the main CS valve. The solenoid controls the pilot valve, which in turn controls the main CS valve. This two-stage control mechanism allows a small solenoid to effectively control a larger valve opening, achieving high refrigerant flow rate without requiring a large solenoid, thus maintaining energy efficiency while improving productivity
Solution Approach 2:
The valve control function is segmented into two independent stages: the pilot valve stage and the main CS valve stage. The pilot valve handles the control signal from the solenoid, while the main CS valve handles the actual refrigerant flow. This segmentation allows each component to be optimized independently - the solenoid remains small and energy-efficient, while the main valve can have a large opening for high flow rate
2Productivity
If the solenoid size and valve opening diameter are enlarged to increase refrigerant flow rate, then the flow rate control capability is improved, but the device size increases
Solution Approach 1:
The pilot valve acts as a mediator that decouples the size relationship between the solenoid and the main valve. The solenoid only needs to be large enough to control the small pilot valve, while the main CS valve can have a large opening for high flow rate. This intermediary structure allows the overall device to remain compact while achieving high productivity
Solution Approach 2:
The pilot valve is nested within or integrated with the main CS valve structure. The pilot valve body is positioned inside the valve housing, and its operation controls the main valve's opening. This nested arrangement allows both valves to occupy overlapping spatial volumes, reducing the overall device size while maintaining the large opening capability of the main valve for high refrigerant flow rate
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 solution reduces the driving power of the solenoid, increases the valve opening degree, and allows for prompt supply of a large flow rate, enhancing energy efficiency and response in variable displacement compressors while maintaining a compact size.
Implementation Method 1
a pilot valve formed of a pilot valve body to be driven by the solenoid
Implementation Method 2
a biasing member that biases the CS valve body in a valve opening direction of the CS valve
Implementation Method 3
the suction fluid is flowable into the second space via an orifice
Data Source
AI summary
A capacity control valve includes a valve housing to which a suction fluid having a suction pressure and a control fluid having a control pressure are supplied; a solenoid; a CS valve body that partitions an inside of the valve housing into a first space, and a second space and moves according to the suction pressure of the suction fluid and the control pressure of the control fluid, and a CS valve seat with which the CS valve body is configured to come into contact; a biasing member biasing the CS valve body in a valve opening direction of the valve; and a pilot valve formed of a pilot valve body to be driven by the solenoid and a pilot valve seat with which the pilot valve body is configured to come into contact.