Refrigerant System Real-Time Diagnostics Using Pressure Delta Analysis
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Solution Overview
Problem
Existing refrigerant system diagnostics in vehicles are typically performed when the systems are not in use, which is less feasible in newer electric vehicles where the refrigerant systems operate more frequently, leaving less time for diagnostics with the systems switched off.
Innovation Solution
A refrigerant system and method that allows for real-time diagnostics while the system is operational, using sensors and processors to measure pressures and temperatures, calculate delta values, and perform remedial actions such as closing valves or stopping the compressor when deviations exceed threshold values, thereby identifying and addressing issues during normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If refrigerant system diagnostics are performed while the system is not in use, then diagnostic accuracy is improved, but system availability and productivity deteriorate due to less time available for diagnostics in vehicles where refrigerant systems operate frequently
Solution Approach 1:
The diagnostic system transitions from static offline diagnostics to dynamic online diagnostics. The system continuously monitors refrigerant parameters (pressure, temperature, flow rate) while the refrigerant system is operating, enabling real-time fault detection without requiring system shutdown. This dynamic approach resolves the contradiction by making diagnostics adaptable to the operational state of the system.
Solution Approach 2:
The diagnostic monitoring operates continuously during refrigerant system operation rather than intermittently when the system is off. Sensors continuously measure parameters and the processor continuously analyzes data streams, ensuring uninterrupted diagnostic coverage while the system runs, thus maintaining both diagnostic capability and system productivity simultaneously.
2Object-affected harmful factors
If refrigerant system diagnostics are performed with the system switched off, then safety during diagnostics is improved, but diagnostic timing and productivity worsen due to limited windows for offline diagnostics
Solution Approach 1:
The system replaces mechanical shutdown requirements with electronic/sensor-based monitoring. Instead of requiring physical system shutdown to perform diagnostics safely, the invention uses electronic sensors and processors to monitor system parameters during operation, substituting the mechanical safety approach with an electronic monitoring approach that allows continuous diagnostics.
Solution Approach 2:
Sensors act as intermediaries between the operating refrigerant system and the diagnostic processor. These sensors safely interface with the running system to extract diagnostic information without requiring direct contact or shutdown, mediating between the operational system and the diagnostic analysis function.
3Reliability
If multiple sensors and processors are added for real-time diagnostics, then diagnostic capability and reliability are improved, but device complexity increases
Solution Approach 1:
The diagnostic system uses multi-functional sensors and processors that serve both operational control and diagnostic monitoring functions. The same pressure sensors, temperature sensors, and flow meters used for system control also provide diagnostic data, eliminating the need for separate dedicated diagnostic hardware and reducing overall system complexity while maintaining diagnostic reliability.
Solution Approach 2:
The invention merges the diagnostic function with the existing control system architecture. Sensors, processors, and communication interfaces are combined into an integrated system where diagnostic capabilities are embedded within the operational control structure, reducing the number of separate components and simplifying the overall system design.
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
Enables real-time monitoring and fault detection within the refrigerant system, ensuring system health and reducing downtime by performing diagnostics while the system is operational, thus improving the reliability and efficiency of refrigerant system diagnostics in electric vehicles.
Implementation Method 1
The first high-side pressure sensor is in fluid communication with the outlet port of the compressor, and is configured to measure the first high-side pressure of the refrigerant
Implementation Method 2
The second high-side pressure sensor is in fluid communication with the inlet port of the compressor, and is configured to measure a second high-side pressure of the refrigerant
Implementation Method 3
The compressor has an inlet port and an outlet port, and is configured to present a refrigerant at a first high-side pressure at the outlet port
Data Source
AI summary
A refrigerant system includes a compressor, multiple pressure sensors, multiple refrigerant flow valves, and a processor. The compressor is configured to present a refrigerant at a first pressure. A first pressure sensor is configured to measure the first pressure of the refrigerant. A second pressure sensor is configured to measure a second pressure of the refrigerant. The refrigerant flow valves have a plurality of flow valve positions. The processor is configured to calculate a delta value as a difference between the first pressure and the second pressure, calculate an expected delta value between the first pressure and the second pressure based on a ratio of a low-side density of the refrigerant at the compressor to the flow valve positions, and perform a remedial action where the delta value deviates from the expected delta value by greater than a threshold value.