Universal Base Unit Modular Air Conditioning System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing air conditioning systems for vehicles require a high number of unique parts and complex assembly processes due to varying vehicle specifications, leading to inefficiencies and increased material waste, as each system configuration necessitates distinct components and designs.
Innovation Solution
A modular approach using a universal base unit with open-circuit refrigerant lines, combined with interchangeable completion kits (front box kit, compressor kit, and alternator-powered compressor kit) that can be configured to meet different operational requirements, reducing the need for multiple unique parts and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple unique air conditioning system designs are produced to meet different vehicle specifications, then adaptability to various vehicle needs is improved, but device complexity and part duplication increase
Solution Approach 1:
The patent implements a universal base unit design that can accommodate multiple compressor configurations (remote, integrated, and intermediate). The base unit includes standardized mounting structures, refrigerant line connections, and control interfaces that work with all compressor types, eliminating the need for unique system designs for each vehicle specification.
Solution Approach 2:
The air conditioning system is divided into modular components: a universal base unit and interchangeable compressor assemblies. This segmentation allows the base unit to remain standardized while only the compressor portion varies according to vehicle needs, reducing overall part complexity while maintaining adaptability.
2Ease of manufacture
If standalone designs are produced for each air conditioning system configuration, then material efficiency for each specific configuration is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The universal base unit is pre-configured with standardized mounting locations, refrigerant line connections, and control interfaces during manufacturing. This preliminary preparation allows for rapid assembly of different compressor configurations without requiring complex field modifications or custom fabrication, significantly reducing assembly time while maintaining material efficiency.
3Adaptability or versatility
If a universal frame and housing structure is designed to accommodate all possible hardware configurations, then adaptability is improved, but material waste and space inefficiency increase
Solution Approach 1:
The universal base unit incorporates localized adaptation features at specific mounting points and connection interfaces, rather than requiring the entire frame and housing structure to accommodate all configurations. This allows the majority of the structure to be optimized for a standard configuration while only specific local areas provide the necessary flexibility for different compressor types, minimizing material waste.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
A method of constructing modular air conditioning systems for vehicles includes providing identical universal base units that can be built out into a variety of different types of air conditioning systems. Each base unit includes a frame, a condenser, an evaporator coil, and a blower, and has open-circuit refrigerant connection lines so as to be non-operational without a completion kit. Completion kits are provided in a variety of configurations, including at least two of a simple connection kit, a front box kit, and a compressor kit, each of which is connectable with a universal base unit to form a unique type of air conditioning system.