Two-Stage Vehicle Air Compressor Cooling for Noise and Heat Control
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Solution Overview
Problem
Existing compressed air generation units for vehicle pneumatic systems, particularly in battery-electric vehicles, face issues with noise, reduced lifespan, and increased costs due to inefficient cooling and heat management, leading to overheating and damage.
Innovation Solution
A two-stage compressed air generation unit with cooling devices thermally coupled to the vehicle's thermal management system, allowing for efficient heat dissipation and reduced noise through liquid cooling, and enabling the use of waste heat for vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single-cylinder compressor with eccentric shaft and connecting rod is used for air suspension systems, then the system can achieve the required compressed air generation, but high levels of noise and vibration occur requiring complex second-order mass balancing
Solution Approach 1:
The compressor is divided into two separate cylinders instead of using a single-cylinder design. Each cylinder operates independently with its own piston, crankshaft journal, and valve arrangement. This segmentation balances the inertial forces and reduces vibration and noise while maintaining the required compressed air generation capability.
2Object-generated harmful factors
If the compressor is enclosed in an enclosure to reduce noise, then acoustic insulation is improved, but heat dissipation becomes difficult leading to overheating
Solution Approach 1:
The enclosure is designed with differentiated thermal properties: the housing provides acoustic insulation in most areas, while specific regions incorporate heat dissipation features such as heat sinks, ventilation channels, or thermally conductive materials. This allows simultaneous achievement of noise reduction and effective heat dissipation by optimizing local thermal characteristics.
3Temperature
If water cooling is implemented for the compressor, then heat dissipation is improved, but the system complexity increases requiring water connections at the compressor location
Solution Approach 1:
A thermally conductive intermediary structure, such as a heat sink or thermal coupling element, is introduced between the compressor and the existing coolant circuit. This intermediary enables efficient heat transfer from the compressor to the coolant without requiring direct water connections at the compressor location, thus reducing system complexity while maintaining effective cooling.
4Reliability
If compressed air dryers are added to remove moisture, then moisture removal capability is improved, but device complexity and cost increase
Solution Approach 1:
The compressed air dryer function is integrated into the existing compressor housing or cooling system structure. The dryer components, such as desiccant material or cooling channels for condensation removal, are combined with the compressor assembly rather than being separate units. This merging reduces overall system complexity and space requirements while maintaining effective moisture removal capability.
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 extends the lifespan of the compressed air generation unit, reduces noise and costs, and enhances the vehicle's thermal management by utilizing waste heat for heating purposes, improving the battery-electric vehicle's range and comfort.
Implementation Method 1
at least one cooling device (11, 13) which is designed for thermal coupling to a thermal management system (2) of the vehicle
Implementation Method 2
at least one cooling device is provided for cooling at least between the first and the second pressure level
Implementation Method 3
the at least one cooling device is designed for thermal coupling to a thermal management system (2) of the vehicle
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
In a compressed air generation unit (1) for generating compressed air for a pneumatic system (6) of a vehicle, in particular a battery-electric vehicle (3), the compressed air generation unit (1) comprises at least two compressor stages (10, 12), wherein a first pressure level (p2) is achievable or is reached after a first compressor stage (10) and a second pressure level (p3) is achievable or is reached after a second compressor stage (12), and at least one cooling device (11, 13) is provided for cooling at least between the first and the second pressure level (p2, p3), wherein the at least one cooling device (11, 13) is designed for thermal coupling with a thermal management system (2) of the vehicle (3).In a battery-electric vehicle (3), in particular a land vehicle, comprising at least one pneumatic system (6) and at least one thermal management system (2), wherein the at least one thermal management system (2) comprises at least one coolant circuit (29) with at least one coolant line (26, 27, 28, 52, 54, 56, 58), and wherein the pneumatic system (6) comprises at least one such compressed air generation unit (1), the thermal management system (2) and the pneumatic system (6) are thermally coupled or coupled for heat removal from the pneumatic system (6) and for heat input into the thermal management system (2).