U.S. patent application number 13/024018 was filed with the patent office on 2012-08-09 for hvac-apu systems for battery electric vehicles.
This patent application is currently assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC. Invention is credited to John R. BUCKNELL, Edward D. TATE, JR..
Application Number | 20120198875 13/024018 |
Document ID | / |
Family ID | 46547182 |
Filed Date | 2012-08-09 |
United States Patent
Application |
20120198875 |
Kind Code |
A1 |
TATE, JR.; Edward D. ; et
al. |
August 9, 2012 |
HVAC-APU SYSTEMS FOR BATTERY ELECTRIC VEHICLES
Abstract
A HVAC-APU system is provided for a battery electric vehicle.
The system includes, but is not limited to a refrigerant fluid. A
power cycle loop section, a cabin heating cycle loop section, and a
cabin refrigeration cycle loop section are in selective fluid
communication with each other to advance the refrigerant fluid
through the system. A compressor-expander train includes, but is
not limited to a reversing compressor-expander and a high-pressure
pump that are operably connected by a shaft. The high-pressure pump
pressurizes the refrigerant fluid to form a high-pressure
refrigerant fluid. An auxiliary fuel cell and combustion unit heats
a heat transfer fluid. A heat exchanger transfers heat from the
heated transfer fluid to the high-pressure refrigerant fluid to
form a heated high-pressure refrigerant fluid. The reversing
compressor-expander expands the heated high-pressure refrigerant
fluid to rotate the shaft in a first direction to drive the
high-pressure pump.
Inventors: |
TATE, JR.; Edward D.; (Grand
Blanc, MI) ; BUCKNELL; John R.; (Royal Oak,
MI) |
Assignee: |
GM GLOBAL TECHNOLOGY OPERATIONS
LLC
DETROIT
MI
|
Family ID: |
46547182 |
Appl. No.: |
13/024018 |
Filed: |
February 9, 2011 |
Current U.S.
Class: |
62/222 ;
62/238.7 |
Current CPC
Class: |
B60L 1/003 20130101;
B60H 1/00428 20130101; B60H 1/00392 20130101; Y02T 90/16 20130101;
B60L 2240/34 20130101; Y02T 10/88 20130101 |
Class at
Publication: |
62/222 ;
62/238.7 |
International
Class: |
F25B 41/04 20060101
F25B041/04; F25B 27/00 20060101 F25B027/00 |
Claims
1. A HVAC-APU system for an electric vehicle, the system
comprising: a refrigerant fluid; a power cycle loop section
configured to advance the refrigerant fluid; a cabin heating cycle
loop section in selective fluid communication with the power cycle
loop section and configured to advance the refrigerant fluid; a
cabin refrigeration cycle loop section in selective fluid
communication with the power cycle loop section and the cabin
heating cycle loop section and configured to advance the
refrigerant fluid with the power cycle loop section and the cabin
heating cycle loop section; a compressor-expander train comprising
a reversing compressor-expander, a high-pressure pump and a shaft
that operably couples the reversing compressor-expander with the
high-pressure pump, the high-pressure pump disposed along the power
cycle loop section and configured to pressurize the refrigerant
fluid to form a high-pressure refrigerant fluid; an auxiliary fuel
cell and combustion unit containing a heat transfer fluid and
configured to heat the heat transfer fluid to form a heated
transfer fluid; and a heat exchanger disposed along the power cycle
loop section to receive the high-pressure refrigerant fluid and is
in fluid communication with the auxiliary fuel cell and combustion
unit to receive the heated transfer fluid, the heat exchanger
configured to transfer heat from the heated transfer fluid to the
high-pressure refrigerant fluid to form a heated high-pressure
refrigerant fluid, wherein the reversing compressor-expander is in
selective fluid communication with the heat exchanger to receive
the heated high-pressure refrigerant fluid and is configured to
expand the heated high-pressure refrigerant fluid to rotate the
shaft in a first direction to drive the high-pressure pump.
2. The system according the claim 1, wherein the
compressor-expander train further comprises a motor generator
operably coupled to the reversing compressor-expander by the shaft,
and wherein the motor generator is configured to be driven by the
shaft rotating in the first direction to generate electrical energy
to define a power generation mode.
3. The system according to claim 2, further comprising a battery
configured to store the electrical energy generated during the
power generation mode.
4. The system according to claim 2, further comprising an electric
motor configured to operably drive the electric vehicle during the
power generation mode with the electrical energy.
5. The system according to claim 2, further comprising a cabin
evaporator disposed along the cabin heating cycle loop section that
is in selective fluid communication with the heat exchanger and
configured to receive the heated high-pressure refrigerant fluid,
the cabin evaporator further configured to extract heat from the
heated high-pressure refrigerant fluid for heating a passenger
cabin of the electric vehicle.
6. The system according to claim 5, wherein the system is operable
in a cabin heating mode and the power generation mode when the
power cycle loop section and the cabin heating cycle loop section
are in fluid communication.
7. The system according to claim 5, further comprising: a primary
loop condenser in fluid communication with the reversing
compressor-expander and configured to receive the refrigerant
fluid; an expansion valve disposed along the cabin refrigeration
cycle loop section that is in selective fluid communication with
the primary loop condenser to receive the refrigerant fluid; a
cabin condenser disposed along the cabin refrigeration cycle loop
section that is in selective fluid communication with the primary
loop condenser to receive the refrigerant fluid, the expansion
valve and the cabin condenser cooperatively configured to expand
and cool the refrigerant fluid for cooling the passenger cabin; and
a linear solenoid ejector AC pump in selective fluid communication
with the heat exchanger and the cabin refrigeration cycle loop
section and configured to receive the heated high-pressure
refrigerant fluid and the refrigerant fluid, the linear solenoid
ejector AC pump further configured to advance the heated
high-pressure refrigerant fluid and the refrigerant fluid producing
a pressure drop across the cabin refrigeration cycle loop section
to advance the refrigerant fluid through the expansion valve and
the cabin condenser.
8. The system according to claim 7, wherein the system is operable
in a cabin cooling mode and the power generation mode when the
power cycle loop section and the cabin refrigeration cycle loop
section are in fluid communication.
9. The system according to claim 7, wherein the system is operable
in a cabin demisting mode and the power generation mode when the
power cycle loop section, the cabin heating cycle loop section and
the cabin refrigeration cycle loop section are in fluid
communication.
10. The system according to claim 7, wherein the motor generator is
configured to be driven by battery stored electrical energy to
rotate the shaft in a second direction in a non-power generation
mode when the reversing compressor-expander is not in fluid
communication with the heat exchanger of the power cycle loop
section, and wherein the reversing compressor-expander is
configured to compress the refrigerant fluid when rotated by the
shaft in the second direction to form a compressed refrigerant
fluid.
11. The system according to claim 10, wherein the cabin evaporator
is configured to extract heat from the compressed refrigerant fluid
for heating the passenger cabin when the cabin evaporator of the
cabin heating cycle loop section is not in fluid communication with
the heat exchanger of the power cycle loop section but is in fluid
communication with the reversing compressor-expander to receive the
compressed refrigerant fluid.
12. The system according to claim 10, wherein the expansion valve
and the cabin condenser are cooperatively configured to expand and
cool the compressed refrigerant fluid for cooling the passenger
cabin when the linear solenoid ejector AC pump is not in fluid
communication with the heat exchanger of the power cycle loop
section but the primary loop condenser is in fluid communication
with the reversing compressor-expander to receive the compressed
refrigerant fluid.
13. The system according to claim 1, further comprising a
circulation pump in fluid communication with the heat transfer
fluid and operably coupled to the shaft to advance the heated
transfer fluid from the auxiliary fuel cell and combustion unit to
the heat exchanger in response to the shaft rotating in the first
direction.
14. The system according to claim 1, wherein the auxiliary fuel
cell and combustion unit is removably connected to the system.
15. A HVAC-APU system for a battery electric vehicle that has a
passenger cabin, the HVAC-APU system configured to receive an
auxiliary fuel cell and combustion unit that contains a heat
transfer fluid and which is operable to heat the heat transfer
fluid to form a heated transfer fluid, the system comprising: a
refrigerant fluid; a power cycle loop section, a cabin heating
cycle loop section, and a cabin refrigeration cycle loop section
that are in selective fluid communication with each other to
advance the refrigerant fluid through the system to provide various
operating modes; a compressor-expander train comprising a reversing
compressor-expander, a high-pressure pump and a shaft that operably
couples the reversing compressor-expander with the high-pressure
pump, the high-pressure pump disposed along the power cycle loop
section and configured to pressurize the refrigerant fluid to form
a high-pressure refrigerant fluid; and a heat exchanger disposed
along the power cycle loop section to receive the high-pressure
refrigerant fluid, the heat exchanger configured for fluid
communication with the auxiliary fuel cell and combustion unit to
receive the heated transfer fluid and to transfer heat from the
heated transfer fluid to the high-pressure refrigerant fluid to
form a heated high-pressure refrigerant fluid, wherein the
reversing compressor-expander is in selective fluid communication
with the heat exchanger to receive the heated high-pressure
refrigerant fluid and is configured to expand the heated
high-pressure refrigerant fluid to rotate the shaft in a first
direction to drive the high-pressure pump.
16. The system according to claim 15, wherein the
compressor-expander train further comprises a motor generator
operably coupled to the reversing compressor-expander by the shaft,
and wherein the motor generator is configured to be driven by the
shaft rotating in the first direction to generate electrical energy
to define a power generation mode.
17. The system according to claim 15, further comprising a cabin
evaporator disposed along the cabin heating cycle loop section that
is in selective fluid communication with the heat exchanger to
receive the heated high-pressure refrigerant fluid, the cabin
evaporator configured to extract heat from the heated high-pressure
refrigerant fluid for heating the passenger cabin.
18. The system according to claim 15, further comprising: a primary
loop condenser in fluid communication with the reversing
compressor-expander to receive the refrigerant fluid; an expansion
valve and a cabin condenser that are disposed along the cabin
refrigeration cycle loop section that is in selective fluid
communication with the primary loop condenser to receive the
refrigerant fluid, the expansion valve and the cabin condenser
cooperatively configured to expand and cool the refrigerant fluid
for cooling the passenger cabin; and a linear solenoid ejector AC
pump in selective fluid communication with the heat exchanger and
the cabin refrigeration cycle loop section to receive the heated
high-pressure refrigerant fluid and the refrigerant fluid,
respectively, the linear solenoid ejector AC pump configured to
advance the heated high-pressure refrigerant fluid and the
refrigerant fluid therethrough so as to cause a pressure drop
across the cabin refrigeration cycle loop section to advance the
refrigerant fluid through the expansion valve and the cabin
condenser.
19. The system according to claim 15, further comprising a
circulation pump operably coupled to the shaft and configured for
fluid communication with the heat transfer fluid to advance the
heated transfer fluid from the auxiliary fuel cell and combustion
unit to the heat exchanger in response to the shaft rotating in the
first direction.
20. The system according to claim 15, further comprising a
plurality of quick connects for removably connecting the auxiliary
fuel cell and combustion unit to the system.
Description
TECHNICAL FIELD
[0001] The technical field relates generally to heating,
ventilation and air-conditioning (HVAC) and auxiliary power unit
(APU) systems for use in vehicles, and more particularly relates to
HVAC and APU systems for use in battery electric vehicles.
BACKGROUND
[0002] Internal combustion engine powered vehicles have been
commercially marketed for over a century and dominate the vehicle
industry. Despite their widespread use, gasoline fueled internal
combustion engines have been associated with a number of issues.
First, due to the finite size and limited regional availability of
fossil fuels, major price fluctuations and a generally upward
pricing trend in the cost of gasoline are common, both of which can
have an impact at the consumer level. Second, fossil fuel
combustion has been associated with environmental problems, such
as, for example, exhaust emissions including concerns over
emissions of carbon dioxide, a greenhouse gas, and a contributor to
global warming. Accordingly, considerable effort has been spent on
finding alternative drive systems for use in both personal and
commercial vehicles.
[0003] Battery electric vehicles offer a promising alternative to
vehicles that use internal combustion drive trains. A battery
electric vehicle is a type of electric vehicle (EV) that uses
chemical energy stored in rechargeable battery, e.g., rechargeable
battery packs, to provide electric power to an electric motor,
instead of an internal combustion engine, for propulsion. However,
there are two main issues with using a battery electric
vehicle.
[0004] The two main issues are concerns about the drivable range
before running out of a battery charge, which is commonly referred
to as range anxiety, and what to do if the battery packs do run out
of energy. Typical drivable ranges for battery electric vehicles
are about 70 miles. However, these ranges depend considerably upon
the age of the battery packs, the driving conditions and the
driving habits of the driver. Moreover, many battery electric
vehicles are unsuitable for towing due to potential damage that can
occur to the transmission if the vehicle is towed. In such cases, a
battery electric vehicle that becomes stranded on a roadside may
require the use of a flatbed truck to transport the battery
electric vehicle to the nearest available power outlet for
recharging the battery packs.
[0005] Concerns over range anxiety and what to do if the battery
packs do run out of energy are further exacerbated when a battery
electric vehicle is driven in an environment that calls for
on-demand heating and/or cooling within the passenger cabin to
provide occupant comfort and/or safety. This is because the HVAC
system for a battery electric vehicle typically operates using
electrical energy from the battery packs, and the energy necessary
to keep the passenger cabin comfortable in relatively extreme
conditions can be on par with the same energy requirements needed
to move the battery electric vehicle down the road.
[0006] For example, operating the heating mode of an HVAC system
for a battery electric vehicle at 10.degree. F. outside conditions
can reduce the drivable range of the battery electric vehicle from
about 70 miles to about 35 miles. Moreover, if the energy charge
does run out of the battery packs and the battery electric vehicle
is stranded on a roadside, there is no electrical energy from the
battery packs to operate the HVAC system while the occupants wait
to be transported to the nearest available power outlet for
recharging the battery packs.
[0007] Accordingly, it is desirable to provide an HVAC system for a
battery electric vehicle that is operational when the energy charge
runs out of the battery packs. Moreover, it is desirable to provide
a battery electric vehicle with extended range capability to reduce
range anxiety. Also, it is desirable to provide a battery electric
vehicle with better options and less expense if the battery packs
do run out of energy and the vehicle needs to be transported to the
nearest available power outlet for recharging the battery packs.
Furthermore, other desirable features and characteristics of the
present invention will become apparent from the subsequent detailed
description and the appended claims, taken in conjunction with the
accompanying drawings and this background.
SUMMARY
[0008] HVAC-APU systems for battery electric vehicles that have
passenger cabins are provided herein. In an exemplary embodiment, a
HVAC-APU system comprises a refrigerant fluid. A power cycle loop
section is configured to advance the refrigerant fluid. A cabin
heating cycle loop section is in selective fluid communication with
the power cycle loop section and is configured to advance the
refrigerant fluid. A cabin refrigeration cycle loop section is in
selective fluid communication with the power cycle loop section and
the cabin heating cycle loop section and is configured to advance
the refrigerant fluid with the power cycle loop section and the
cabin heating cycle loop section. A compressor-expander train
comprises a reversing compressor-expander, a high-pressure pump and
a shaft that operably couples the reversing compressor-expander
with the high-pressure pump. The high-pressure pump is disposed
along the power cycle loop section and is configured to pressurize
the refrigerant fluid to form a high-pressure refrigerant fluid. An
auxiliary fuel cell and combustion unit contains a heat transfer
fluid and is configured to heat the heat transfer fluid to form a
heated transfer fluid. A heat exchanger is disposed along the power
cycle loop section to receive the high-pressure refrigerant fluid
and is in fluid communication with the auxiliary fuel cell and
combustion unit to receive the heated transfer fluid. The heat
exchanger is configured to transfer heat from the heated transfer
fluid to the high-pressure refrigerant fluid to form a heated
high-pressure refrigerant fluid. The reversing compressor-expander
is in selective fluid communication with the heat exchanger to
receive the heated high-pressure refrigerant fluid and is
configured to expand the heated high-pressure refrigerant fluid to
rotate the shaft in a first direction to drive the high-pressure
pump.
[0009] In accordance with another exemplary embodiment, a HVAC-APU
system for a battery electric vehicle that has a passenger cabin is
provided herein. The HVAC-APU system is configured to receive an
auxiliary fuel cell and combustion unit that contains a heat
transfer fluid and which is operable to heat the heat transfer
fluid to form a heated transfer fluid. The system comprises a
refrigerant fluid. A power cycle loop section, a cabin heating
cycle loop section, and a cabin refrigeration cycle loop section
are in selective fluid communication with each other to advance the
refrigerant fluid through the system to provide various operating
modes. A compressor-expander train comprises a reversing
compressor-expander, a high-pressure pump and a shaft that operably
couples the reversing compressor-expander with the high-pressure
pump. The high-pressure pump is disposed along the power cycle loop
section and is configured to pressurize the refrigerant fluid to
form a high-pressure refrigerant fluid. A heat exchanger is
disposed along the power cycle loop section to receive the
high-pressure refrigerant fluid. The heat exchanger is configured
for fluid communication with the auxiliary fuel cell and combustion
unit to receive the heated transfer fluid and to transfer heat from
the heated transfer fluid to the high-pressure refrigerant fluid to
form a heated high-pressure refrigerant fluid. The reversing
compressor-expander is in selective fluid communication with the
heat exchanger to receive the heated high-pressure refrigerant
fluid and is configured to expand the heated high-pressure
refrigerant fluid to rotate the shaft in a first direction to drive
the high-pressure pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments of the present invention will hereinafter be
described in conjunction with the following drawing figures,
wherein like numerals denote like elements, and wherein:
[0011] FIG. 1 is a schematic depiction of a HVAC-APU system for a
battery electric vehicle in a heating mode in accordance with an
exemplary embodiment;
[0012] FIG. 2 is a schematic depiction of a HVAC-APU system for a
battery electric vehicle in a refrigeration mode in accordance with
an exemplary embodiment;
[0013] FIG. 3 is a schematic depiction of a HVAC-APU system for a
battery electric vehicle in a heating mode and a power generation
mode in accordance with an exemplary embodiment;
[0014] FIG. 4 is a schematic depiction of a HVAC-APU system for a
battery electric vehicle in a refrigeration mode and a power
generation mode in accordance with an exemplary embodiment; and
[0015] FIG. 5 is a schematic depiction of a HVAC-APU system for a
battery electric vehicle in a demisting mode and a power generation
mode in accordance with an exemplary embodiment.
DETAILED DESCRIPTION
[0016] The following Detailed Description is merely exemplary in
nature and is not intended to limit the invention or the
application and uses of the invention. Furthermore, there is no
intention to be bound by any theory presented in the preceding
Background or the following Detailed Description.
[0017] Various embodiments contemplated herein relate to HVAC-APU
systems for a battery electric vehicle. The system has a power
cycle loop section, a cabin heating cycle loop section, and a cabin
refrigeration cycle loop section that are in selective fluid
communication with each other to direct a refrigerant fluid through
the system to provide various HVAC and/or APU operating modes. In
particular, the power cycle loop section is configured for
supporting a power generation mode for producing electrical energy
that may be stored in the battery packs to extend the vehicle's
drivable range, or alternatively, that may be directed to the
vehicle's electric motor to be used as an emergency range extender
to propel the vehicle without the assistance of electrical energy
from the battery packs. The cabin heating cycle loop section is
configured for supporting a cabin heating mode for heating the
passenger cabin of the battery electric vehicle, and the cabin
refrigeration cycle loop section is configured for supporting a
cabin cooling mode for cooling the passenger cabin. The cabin
heating mode and/or the cabin cooling mode may be performed using
electrical energy from the battery packs, or alternatively, may be
performed in conjunction with the power generation mode without
using electrical energy from the battery packs.
[0018] In an exemplary embodiment, the APU portion of the system
includes a removable auxiliary fuel cell and combustion unit and a
compressor-expander train that is integrated with the HVAC portion
of the system. The compressor-expander train has a reversing
compressor-expander, a high-pressure pump, a shaft and preferably a
motor generator. The shaft operably couples the reversing
compressor-expander to the high-pressure pump and the motor
generator. The high-pressure pump is disposed along the power cycle
loop section and is configured to pressurize the refrigerant fluid
to form a high-pressure refrigerant fluid. The auxiliary fuel cell
and combustion unit contains a heat transfer fluid that is heated
by combusting fuel that is stored in the unit.
[0019] A heat exchanger is disposed along the power cycle loop
section to receive the high-pressure refrigerant fluid and is in
fluid communication with the auxiliary fuel cell and combustion
unit to receive the heated transfer fluid. The heat exchanger
transfers heat from the heated transfer fluid to the high-pressure
refrigerant fluid to form a heated high-pressure refrigerant fluid.
In an exemplary embodiment, the heated high-pressure refrigerant
fluid is fluidly communicated to and expanded by the reversing
compressor-expander to rotate the shaft to drive the high-pressure
pump, and further, to drive the motor generator to generate
electrical energy for the power generation mode.
[0020] In another exemplary embodiment, the cabin heating mode is
performed without using electrical energy from the vehicle's
battery packs. In particular, the heated high-pressure refrigerant
fluid from the heat exchanger is fluidly communicated to a cabin
evaporator that is disposed along the cabin heating cycle loop
section. The cabin evaporator extracts heat from the heated
high-pressure refrigerant fluid to provide heat to the passenger
cabin for the cabin heating mode.
[0021] In another exemplary embodiment, the cabin cooling mode is
performed without using electrical energy from the vehicle's
battery packs. In particular, the heated high-pressure refrigerant
fluid from the heat exchanger is advanced through a linear solenoid
injector AC pump, which is in fluid communication with the cabin
refrigeration cycle loop section, causing a pressure drop across
the cabin refrigeration cycle loop section. An expansion valve and
a cabin condenser are disposed along the cabin refrigeration cycle
loop section, and the pressure drop causes the refrigerant fluid in
the cabin refrigeration cycle loop section to advance through the
expansion valve and the cabin condenser, expanding and cooling the
refrigerant fluid to provide cooling to the passenger cabin for the
cabin cooling mode.
[0022] Thus, the HVAC-APU system is operational to perform the
cabin heating and/or cooling modes without using electrical energy
from the vehicle's battery packs, such as, for example, when the
energy charge runs out of the battery packs. Moreover, electrical
energy produced during the power generation mode may be stored in
the battery packs to extend the vehicle's drivable range to reduce
range anxiety. Furthermore, energy produced during the power
generation mode may be directed to the vehicle's electric motor to
be used as an emergency range extender to propel the vehicle to the
nearest available power outlet if the battery packs run out of
energy without otherwise having the expense of transporting the
vehicle, e.g., via a flatbed truck or the alike.
[0023] Referring to FIG. 1, a schematic depiction of an exemplary
embodiment of the HVAC-APU system 10 for a battery electric vehicle
operating in a cabin heating mode using battery stored electrical
energy is provided. The system 10 includes a HVAC portion 12 and a
partially integrated APU portion 14. The HVAC portion 12 is charged
with refrigerant fluid and is configured to preferably operate
under Rankine cycle conditions as is well known in the art so that
the refrigerant fluid is typically expanded in a gas phase and
pumped in a liquid phase. The APU portion 14 includes an auxiliary
fuel cell and combustion unit 15, and various functioning elements
integrated into the HVAC portion 12 along a compressor-expander
train 16. The compressor-expander train 16 includes a reversing
compressor-expander 18, a high-pressure pump 20, a motor generator
22 and a shaft 24 that operably couples the high-pressure pump 20
and the motor generator 22 with the reversing compressor-expander
18. The various functioning elements of the APU portion 14
integrated along the compressor-expander train 16 include a fluid
expander function of the reversing compressor-expander 18, the
high-pressure pump 20 and the electric generator function of the
motor generator 22 as will be explained in greater detail
below.
[0024] As illustrated, the system 10 is operating in a cabin
heating mode where the refrigerant fluid is advanced along a
heating cycle loop 26 indicated by lines 1, 2, 3, 4 and 5, and a
cabin heating cycle loop section 28 that are illustrated in bold.
In particular, the motor generator 22 is driven by electrical
energy provided from the battery packs 30 to rotate the shaft 24 in
a direction (e.g., compression direction) that drives the reversing
compressor-expander 18 to compress the refrigerant fluid that is
provided from line 1 to form a compressed-heated refrigerant fluid.
The compressed-heated refrigerant fluid is passed along line 2 to a
mode selection valve 32 that directs the compressed-heated
refrigerant fluid to the cabin heating cycle loop section 28 via
line 3 and the mode selection valve 34.
[0025] Dispose along the cabin heating cycle loop section 28 are a
cabin evaporator 36 and an expansion valve 38. As is known in the
art, the cabin evaporator 36 extracts heat from the
compressed-heated refrigerant fluid, and air passing over the cabin
evaporator 36 carries at least a portion of the heat into the
passenger cabin. The expansion valve 38 expands the refrigerant
fluid that is then fluidly communicated through a condenser 40,
which is also referred to as the primary loop condenser, a
recuperating heat exchanger 42, a liquid-gas separator 44, a bypass
valve 46, a linear solenoid injector AC pump 48 and the reversing
compressor-expander 18 via lines 4, 5 and 1, respectively, to
complete the heating cycle loop 26.
[0026] Referring to FIG. 2, a schematic depiction of an exemplary
embodiment of the HVAC-APU system 10 operating in a cabin cooling
mode using battery stored electrical energy is provided. As
illustrated, the refrigerant fluid is advanced along a
refrigeration cycle loop 50 indicated by lines 1, 2, 3, 6, 4 and 7,
and a cabin refrigeration cycle loop section 52 that are
illustrated in bold. In particular, the motor generator 22 is
driven by electrical energy provided from the battery packs 30 to
rotate the shaft 24 in the compression direction, driving the
reversing compressor-expander 18 to compress the refrigerant fluid
provided from line 1 to form the compressed-heated refrigerant
fluid. The compressed-heated refrigerant fluid is passed along line
2 to the mode selection valve 32 that directs the compressed-heated
refrigerant fluid to the condenser 40 via mode selection valve 34
and line 6. Some of the heat is removed from the compressed-heated
refrigerant fluid in the condenser 40 and the recuperating heat
exchanger 42 to form a compressed heat-depleted refrigerant fluid
prior to being introduced to the cabin refrigeration cycle loop
section 52 via line 4 and the liquid-gas separator 44. Dispose
along the cabin refrigeration cycle loop section 52 is an expansion
valve 54 and a cabin condenser 56. As is well known in the art, the
expansion valve 54 and the cabin condenser 56 expand and cool the
compressed heat-depleted refrigerant fluid, and air passing over
the cabin condenser 56 is cooled and directed into the passenger
cabin for cooling. The expanded refrigerant fluid is passed from
the cabin refrigeration cycle loop section 52 through the
recuperating heat exchanger 42 to remove some of the heat from the
counter flowing compressed-heat depleted refrigerant fluid, and
then is fluidly communicated to the reversing compressor-expander
18 via line 7, the linear solenoid injector AC pump 48 and line 1,
respectively, to complete the refrigeration cycle loop 50.
[0027] Referring to FIG. 3, a schematic depiction of an exemplary
embodiment of the HVAC-APU system 10 for a battery electric vehicle
operating in a cabin heating mode and a power generation mode is
provided. In this embodiment, the HVAC portion 12 and the APU
portion 14 cooperate to generate electrical energy for the power
generation mode. In particular, the auxiliary fuel cell and
combustion unit 15 includes a fuel cell 58 that is in fluid
communication via line 62 with a combustor 60 to provide fuel for
combustion. The auxiliary fuel cell and combustion unit 15 is
removably connected to the system 10 by a plurality of quick
connects 64 that sealingly coupled together to complete the
transfer fluid loop 66. A circulating pump 68 is dispose along the
transfer fluid loop 66 to circulate heat transfer fluid through the
transfer fluid loop 66. The combustor 60 generates heat by burning
fuel from the fuel cell 58 to heat the heat transfer fluid to a
temperature of from preferably about 200 to about 300.degree.
C.
[0028] As illustrated, the system 10 is operating in both the cabin
heating mode and the power generation mode. For the power
generation mode, the refrigerant fluid is advanced along a power
cycle loop 70 indicated by lines 1, 8, 6, 4 and 9, and a power
cycle loop section 72 that are illustrated in bold. Dispose along
the power cycle loop section 72 are the high pressure pump 20, an
economizer heat exchanger 74 and a refrigerant-to-heat transfer
fluid heat exchanger 76. The high pressure pump 20 pressurizes the
refrigerant fluid to form a high-pressure refrigerant fluid that is
fluidly communicated to the economizer heat exchanger 74, which
moderately increases the temperature of the high-pressure
refrigerant fluid with the counter flowing refrigerant fluid in
line 8 for overall system efficiency, before being introduced to
the refrigerant-to-heat transfer fluid heat exchanger 76. The
refrigerant-to-heat transfer fluid heat exchanger 76, which is in
fluid communication with the auxiliary fuel cell and combustion
unit 15, transfers heat from the heated transfer fluid to the
high-pressure refrigerated fluid to form a heated high-pressure
refrigerant fluid.
[0029] The reversing compressor-expander 18 is in fluid
communication with the power cycle loop section 72 via line 9. The
reversing compressor-expander 18 receives and expands the heated
high-pressure refrigerant fluid to rotate the shaft 24 in a power
generation direction (e.g., opposite the compression direction),
driving the high-pressure liquid pump 20, the circulating pump 68
and a motor generator 22. The motor generator 22 generates
electrical energy in response to being driven by the shaft rotating
in the power generation direction. The generated electrical energy,
for example, may be stored in the battery packs 30 to extend the
vehicle's drivable range, or alternatively, may be directed to the
vehicle's electric motor 78 to be used as an emergency range
extender to propel the vehicle without the assistance of electrical
energy from the battery packs 30.
[0030] For the cabin heating mode performed in conjunction with the
power generation mode, the mode selection valves 32 and 34 direct a
portion of the heated high-pressure refrigerant fluid from the
refrigerant-to-heat transfer fluid heat exchanger 76 to the cabin
heating cycle loop section 28 via lines 2 and 3. The cabin
evaporator 36 extracts heat from the heated high-pressure
refrigerant fluid, and air passing over the cabin evaporator 36
carries some of the heat into the passenger cabin. The expansion
valve 38 expands refrigerant fluid that is then fluidly
communicated to the power cycle loop 70.
[0031] Referring to FIG. 4, a schematic depiction of an exemplary
embodiment of the HVAC-APU system 10 operating in a cabin cooling
mode and a power generation mode is provided. The HVAC portion 12
and the APU portion 14 cooperate to generate electrical energy for
the power generation mode as discussed in the foregoing paragraphs
in relation to FIG. 3.
[0032] For the cabin cooling mode performed in conjunction with the
power generation mode, the mode selection valves 32 and 34 are set
so as to not direct the refrigerant fluid through the cabin heating
cycle loop section 28. The linear solenoid ejector AC pump 48 is in
fluid communication with the cabin refrigeration cycle loop section
52 and the refrigerant-to-heat transfer fluid heat exchanger 76 to
receive two feed streams including the refrigerant fluid from the
cabin refrigeration cycle loop section 52 and the heated
high-pressure refrigerant fluid via lines 7 and 11, respectively.
With the two feed streams, the linear solenoid ejector AC pump 48
functions as a thermal compressor having the heated high-pressure
refrigerant fluid as a high energy motive fluid running through an
acceleration nozzle (e.g., a venturi effect produced from a narrow
to large diffusion nozzle) at supersonic speed such that the slower
adjacent refrigerant fluid from the cabin refrigeration cycle loop
section 52 is sucked in and mixes with the heated high-pressure
refrigerant fluid to produce a pressure drop across line 7 and the
cabin refrigeration cycle loop section 52. The refrigerant fluid
mixture expands and exits the linear solenoid ejector AC pump 48 at
a relatively low velocity and high pressure. The exiting
refrigerant fluid mixture is combined with the refrigerant fluid
exiting the reversing compressor-expander 18 at line 8. The linear
solenoid ejector AC pump 48 may be modulated so that the exiting
refrigerant fluid mixture is at about the same pressure and
temperature, e.g., about 100 to about 120.degree. C., as the
refrigerant fluid stream from the reversing compressor-expander 18
along line 1. The combined refrigerant fluid mixture is then
fluidly communicated to the cabin refrigeration cycle loop section
52 through the economizer heat exchanger 74, line 6, the condenser
40, the recuperating heat exchanger 42, line 4 and the liquid-gas
separator 44.
[0033] The pressure drop across the cabin refrigeration cycle loop
section 52 accelerates the refrigerant fluid, which is at a
relatively high pressure, through the expansion valve 54 and the
cabin condenser 56 to expand and cool the refrigerant fluid. Air
passing over cabin condenser 56 is cooled by the cooled refrigerant
fluid and is directed into the passenger cabin for cooling.
[0034] Referring to FIG. 5, a schematic depiction of an exemplary
embodiment of the HVAC-APU system 10 operating in a cabin demisting
mode and a power generation mode is provided. The HVAC portion 12
and the APU portion 14 cooperate to generate electrical energy for
the power generation mode as discussed in the foregoing paragraphs
in relation to FIG. 3.
[0035] For the cabin demisting mode performed in conjunction with
the power generation mode, both the cabin heating mode and the
cabin cooling mode as discussed in relation to FIGS. 3 and 4 are
performed contemporaneously by directing fluid communication
between the power cycle loop section 72, the cabin heating cycle
loop section 28 and the cabin refrigeration cycle loop section 52
such that the cabin evaporator 36 is heated by the heated
high-pressure refrigerant fluid, and the relatively high pressure
refrigerant fluid from the linear solenoid ejector AC pump 48 and
the reversing compressor-expander 18 is accelerated through the
expansion valve 54 and the cabin condenser 56 to cool the cabin
condenser 56. An air stream is directed over the cooled cabin
condenser 56, which cools and dehumidifies the air, and is
subsequently directed over the heated cabin evaporator 36, which
returns heat back into the cool-dried air, to form a warm-dry air
stream directed towards the passenger cabin for demisting.
[0036] Accordingly, HVAC-APU systems for battery electric vehicles
have been described. The various embodiments comprise a power cycle
loop section, a cabin heating cycle loop section, and a cabin
refrigeration cycle loop section that are in selective fluid
communication with each other to direct a refrigerant fluid through
the system to provide various HVAC and/or APU operating modes. In
particular, the power cycle loop section is configured for
supporting a power generation mode for producing electrical energy
that may be stored in the battery packs to extend the vehicle's
drivable range, or alternatively, that may be directed to the
vehicle's electric motor to be used as an emergency range extender
to propel the vehicle without the assistance of electrical energy
from the battery packs. The cabin heating cycle loop section is
configured for supporting a cabin heating mode for heating the
passenger cabin of the battery electric vehicle, and the cabin
refrigeration cycle loop section is configured for supporting a
cabin cooling mode for cooling the passenger cabin. The cabin
heating mode and/or the cabin cooling mode may be performed using
electrical energy from the battery packs, or alternatively, may be
performed in conjunction with the power generation mode without
using electrical energy from the battery packs. Thus, the HVAC-APU
system is operational to perform the cabin heating and/or cooling
modes without using electrical energy from the vehicle's battery
packs, such as, for example, when the energy charge runs out of the
battery packs. Moreover, electrical energy produced during the
power generation mode may be stored in the battery packs to extend
the vehicle's drivable range to reduce range anxiety. Furthermore,
energy produced during the power generation mode may be directed to
the vehicle's electric motor to be used as an emergency range
extender to propel the vehicle to the nearest available power
outlet if the battery packs run out of energy without otherwise
having the expense of transporting the vehicle, e.g., via a flatbed
truck or the alike.
[0037] While at least one exemplary embodiment has been presented
in the foregoing Detailed Description, it should be appreciated
that a vast number of variations exist. It should also be
appreciated that the exemplary embodiment or exemplary embodiments
are only examples, and are not intended to limit the scope,
applicability, or configuration in any way. Rather, the foregoing
Detailed Description will provide those skilled in the art with a
convenient road map for implementing an exemplary embodiment of the
invention, it being understood that various changes may be made in
the function and arrangement of elements described in an exemplary
embodiment without departing from the scope of as set forth in the
appended Claims and their legal equivalents.
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