Vehicle Heat Pump Chiller Integration for Controller Cooling

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Solution Overview

Problem

Conventional heat pump systems for vehicles are unable to independently cool the autonomous driving controller during heating mode operations, leading to increased manufacturing costs and power consumption due to the need for additional heat-exchangers and high-voltage heaters.

Innovation Solution

A heat pump system for vehicles that includes a first cooling apparatus for electrical components, a second cooling apparatus for battery modules, a third cooling apparatus for autonomous driving controllers, and an air conditioning device with chillers that allow for selective cooling of the autonomous driving controller and simultaneous waste heat recovery during heating mode.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate cooling device is added for the autonomous driving controller, then the cooling function is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecooling functionVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the autonomous driving controller cooling function with the existing air conditioning system by integrating a third cooling apparatus and connecting it to the refrigerant circulation system. The shared components include the compressor, condenser, expansion valve, and evaporator, which serve both the original air conditioning function and the new controller cooling function. This integration eliminates the need for a completely separate cooling system while providing dedicated cooling capability for the autonomous driving controller.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a separate cooling device is added for the autonomous driving controller, then the cooling function is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvecooling functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple cooling devices are added for different components, then the cooling capability is improved, but the space requirement increases

Engineering Contradiction:

Improvecooling capabilityVSAvoidspace requirement

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The refrigerant circulation system is designed to serve multiple functions: it cools the vehicle interior through the air conditioning system and simultaneously cools the autonomous driving controller through the integrated third cooling apparatus. The system achieves multi-functionality by using the same refrigerant loop and shared components to provide cooling for different targets, thereby reducing the overall space requirement compared to having separate independent cooling systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If multiple cooling devices are added for different components, then the cooling capability is improved, but the system weight increases

Engineering Contradiction:

Improvecooling capabilityVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Reliability

If the autonomous driving controller is cooled during heating mode, then the temperature control is improved, but the energy consumption increases

Engineering Contradiction:

Improvetemperature controlVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies the 'blessing in disguise' principle by converting the waste heat generated by the autonomous driving controller into a useful resource for vehicle interior heating. During heating mode operation, the system redirects the hot refrigerant from the condenser through a heat exchanger connected to the third cooling apparatus, where it absorbs heat from the autonomous driving controller. This recovered heat is then utilized for heating the vehicle interior, thereby reducing the energy consumption of the heating system while maintaining effective cooling of the controller.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution enables efficient temperature control of the autonomous driving controller, improves heating efficiency, reduces manufacturing costs by eliminating the need for separate heat-exchangers, and minimizes power consumption by reducing the use of high-voltage electric heaters.

Implementation Method 1

a first chiller connected to the first refrigerant line through a second refrigerant line, connected to the second coolant line, and heat-exchanging the selectively inflowed second coolant with the refrigerant supplied through the second refrigerant line to control a temperature of the second coolant

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

lowers a temperature and a humidity of the interior by condensing a high-temperature high-pressure gas-phase refrigerant compressed from the compressor by the condenser

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

evaporating the refrigerant in the evaporator in a cooling mode

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12251987B2Heat pump system for vehicle

Publication Date: 2025.03.18 HYUNDAI MOTOR CO LTD

AI summary

An embodiment heat pump system for a vehicle includes a first cooling apparatus that circulates a first coolant in a first coolant line to control a temperature of an electrical component, a second cooling apparatus that circulates a second coolant in a second coolant line to control a temperature of a battery module, a third cooling apparatus that circulates a third coolant in a third coolant line to control a temperature of an autonomous driving controller, and an air conditioning device that circulates a refrigerant along a first refrigerant line to control an indoor temperature of the vehicle, the air conditioning device including a compressor, a condenser, a first expansion valve, and an evaporator all connected through the first refrigerant line, and further including a first chiller, a second chiller, and a connection line.