Heavy Duty Truck Air Conditioning System Remote Condenser
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Solution Overview
Problem
Heavy duty trucks face reduced fuel efficiency due to the air conditioning system components, such as the condenser and belt-driven cooling fan, which obstruct airflow and increase engine load, especially in long-distance operations.
Innovation Solution
The method involves removing the condenser and belt-driven cooling fan from the engine bay and installing a remote condenser and electric cooling assembly, with a control unit to activate/deactivate electric fans based on cooling needs, and optionally a remote oil cooler, to reduce engine load and improve airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the condenser and belt-driven cooling fan are installed in the engine bay, then the air conditioning system can cool the engine, but the components obstruct airflow and increase engine load, reducing fuel efficiency
Solution Approach 1:
The condenser and belt-driven cooling fan are removed from the engine bay and relocated to a remote position at the rear of the truck cab. This extraction eliminates the obstruction of airflow through the radiator and reduces the engine load that was required to drive the belt-driven fan, thereby improving fuel efficiency while maintaining engine cooling capability through the electric fan system
Solution Approach 2:
The belt-driven mechanical cooling fan system is replaced with an electrically-powered cooling fan system. The electric fans are controlled independently of the engine's mechanical belt system, allowing for more efficient operation and reduced engine load. The control unit activates or deactivates the electric fans based on actual cooling needs, replacing the continuous mechanical drive with a controlled electrical system
2Device complexity
If the condenser is mounted within the engine bay adjacent to the radiator, then the air conditioning system is compact, but it obstructs airflow through the radiator, reducing cooling efficiency
Solution Approach 1:
The condenser is extracted from its traditional position within the engine bay and relocated to a remote position at the rear of the cab. This removal eliminates the interference with radiator airflow that was causing reduced cooling efficiency, while the air conditioning system remains integrated through the refrigerant lines connecting the remote condenser to the engine bay components
3Device complexity
If the belt-driven cooling fan is used, then the system is mechanically simple, but it increases engine load continuously, reducing fuel efficiency
Solution Approach 1:
The belt-driven mechanical fan system is replaced with an electrically-powered fan system controlled by a control unit. The electric fans are connected to the truck's electrical system rather than the mechanical belt system, eliminating the continuous engine load. The control unit intelligently activates or deactivates the electric fans based on actual cooling requirements, providing simpler mechanical integration with the engine while significantly reducing energy consumption
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 modification increases fuel efficiency by 10% or more, reduces engine load, and extends the lifespan of air filters and engine components, while operating more efficiently under various temperature conditions.
Implementation Method 1
installing an electric cooling assembly in the engine bay adjacent to the radiator of the truck, the electric cooling assembly comprising one or more electrically powered cooling fans
Implementation Method 2
installing a remote condenser on the truck at a location that is external from the engine bay, the remote condenser in fluid communication with the primary air conditioning loop
Implementation Method 3
a condenser mounted within an engine bay of the truck
Data Source
AI summary
A heavy duty truck includes an air conditioning loop having a compressor, a condenser mounted within an engine bay of the truck, an evaporator, and a cooling fan belt-driven by an engine of the truck mounted within the engine bay adjacent a radiator of the truck. A method of modifying the air conditioning loop includes removing the condenser from the engine bay, removing the belt-driven cooling fan from the engine bay, installing a remote condenser on the truck at a location that is external from the engine bay, the remote condenser in fluid communication with the primary air conditioning loop of the truck, installing an electric cooling assembly in the engine bay adjacent to the radiator of the truck, the electric cooling assembly comprising one or more electrically powered cooling fans and a surrounding shroud, and installing a control unit in electrical communication with the one or more cooling fans.