U.S. patent application number 13/080882 was filed with the patent office on 2012-10-11 for vehicle a/c compressor assembly.
Invention is credited to MARK G. SMITH.
Application Number | 20120257996 13/080882 |
Document ID | / |
Family ID | 46966260 |
Filed Date | 2012-10-11 |
United States Patent
Application |
20120257996 |
Kind Code |
A1 |
SMITH; MARK G. |
October 11, 2012 |
VEHICLE A/C COMPRESSOR ASSEMBLY
Abstract
A vehicle a/c compressor assembly for a hybrid or electric
vehicle includes an electric motor housing, an AC electric motor in
the electric motor housing, a compressor housing and a compressor
in the compressor housing. The AC electric motor is drivingly
coupled to the compressor exterior to the motor housing and the
compressor housing.
Inventors: |
SMITH; MARK G.;
(US) |
Family ID: |
46966260 |
Appl. No.: |
13/080882 |
Filed: |
April 6, 2011 |
Current U.S.
Class: |
417/410.1 |
Current CPC
Class: |
F04B 35/04 20130101 |
Class at
Publication: |
417/410.1 |
International
Class: |
F04B 35/04 20060101
F04B035/04 |
Claims
1. A vehicle a/c compressor assembly for a hybrid or electric
vehicle, comprising: an electric motor housing; an AC electric
motor in the electric motor housing; a compressor housing; a
compressor in the compressor housing; and the AC motor drivingly
coupled to the compressor exterior to the electric motor housing
and the compressor housing.
2. The vehicle a/c compressor assembly of claim 1 further
comprising a motor shaft drivingly engaged by the AC motor and a
compressor shaft drivingly engaging the compressor, the motor shaft
drivingly engaging the compressor shaft outside the electric motor
housing and the compressor housing.
3. The vehicle a/c compressor assembly of claim 2 wherein the
compressor shaft is disposed in alignment with the motor shaft.
4. The vehicle a/c compressor assembly of claim 3 further
comprising a shaft coupler coupling the motor shaft and the
compressor shaft.
5. The vehicle a/c compressor assembly of claim 1 wherein the AC
electric motor is a fixed speed motor.
6. The vehicle a/c compressor assembly of claim 1 wherein the AC
electric motor is a variable speed AC motor.
7. The vehicle a/c compressor assembly of claim 1 wherein the
compressor is a fixed displacement compressor.
8. The vehicle a/c compressor assembly of claim 1 wherein the
compressor is a variable displacement compressor.
9. A vehicle a/c compressor assembly for a hybrid or electric
vehicle, comprising: an electric motor housing; an AC electric
motor in the electric motor housing; a compressor housing; a
compressor in the compressor housing; and a drive belt drivingly
coupling the compressor to the AC electric motor exterior to the
compressor housing and the electric motor housing.
10. The vehicle a/c compressor assembly of claim 9 further
comprising a drive belt tensioner engaging the drive belt.
11. The vehicle a/c compressor assembly of claim 9 further
comprising a motor shaft drivingly engaged by the AC electric
motor, a motor pulley carried by the motor shaft, a compressor
shaft drivingly engaging the compressor and a compressor pulley
carried by the compressor shaft, and wherein the drive belt
drivingly engages the motor pulley and the compressor pulley
outside the motor housing and the compressor housing.
12. The vehicle a/c compressor assembly of claim 11 wherein the
compressor shaft is disposed in generally parallel relationship to
the motor shaft.
13. The vehicle a/c compressor assembly of claim 9 wherein the AC
electric motor is a fixed speed motor.
14. The vehicle a/c compressor assembly of claim 9 wherein the AC
electric motor is a variable speed AC motor.
15. The vehicle a/c compressor assembly of claim 9 wherein the
compressor is a fixed displacement compressor.
16. The vehicle AC compressor assembly of claim 9 wherein the
compressor is a variable displacement compressor.
17. A vehicle a/c compressor assembly for a hybrid or electric
vehicle, comprising: an electric motor housing; an AC electric
motor in the electric motor housing; an electric motor shaft
drivingly engaged by the AC motor and extending from the electric
motor housing; an electric motor pulley carried by the electric
motor shaft; a compressor housing; a compressor in the compressor
housing; a compressor shaft drivingly engaging the compressor and
extending from the compressor housing; a compressor pulley carried
by the compressor shaft; a connecting conduit establishing fluid
communication between the electric motor housing and the compressor
housing; and a drive belt drivingly coupling the compressor pulley
to the motor pulley exterior to the compressor housing and the
motor housing.
18. The vehicle a/c compressor assembly of claim 17 wherein the
compressor is a variable displacement compressor.
19. The vehicle a/c compressor assembly of claim 17 wherein the AC
electric motor is a variable speed AC motor.
20. The vehicle a/c compressor assembly of claim 17 wherein the
compressor is a fixed displacement compressor.
Description
FIELD
[0001] The disclosure generally relates to vehicle air conditioner
compressors. More particularly, the disclosure relates to a vehicle
a/c (air conditioning) compressor assembly which is particularly
suitable for hybrid electric vehicles (HEVs), plug-in HEVs and
battery electric vehicles and in which a high-voltage motor and an
a/c compressor from a non-hybrid vehicle are combined as separate
units to reduce repair and replacement costs.
BACKGROUND
[0002] The air conditioning systems of conventional hybrid electric
vehicles (HEVs), plug-in HEVs and battery electric vehicles utilize
a small displacement scroll compressor and an electric drive motor
(AC or DC) which are contained in a common housing. A drive shaft
in the housing couples the scroll compressor to the electric drive
motor. Therefore, in the event that either the compressor or the
drive motor requires replacement, the other component must also be
replaced even though that component may still be functional. This
drawback renders excessively high the cost of replacement of either
component.
[0003] Accordingly, a vehicle a/c compressor assembly is needed
which is particularly suitable for hybrid electric vehicles (HEVs),
plug-in HEVs and battery electric vehicles and in which a
high-voltage motor and an a/c compressor from a non-hybrid vehicle
are combined as separate units to reduce repair and replacement
costs.
SUMMARY
[0004] The disclosure is generally directed to a vehicle a/c
compressor assembly for a hybrid or electric vehicle. An
illustrative embodiment of the a/c compressor assembly includes a
motor housing, an AC motor in the motor housing, a compressor
housing and a compressor in the compressor housing. The AC motor is
drivingly coupled to the compressor exterior to the motor housing
and the compressor housing.
[0005] In some embodiments, the vehicle a/c compressor assembly for
a hybrid or electric vehicle may include a motor housing; an AC
motor in the motor housing; a compressor housing; a compressor in
the compressor housing; and a drive belt drivingly coupling the
compressor to the AC motor exterior to the compressor housing and
the motor housing. The AC motor may be a 3-phase AC motor powered
by an inverter that is part of the assembly. The inverter may feed
a range of voltages such as 300V DC power, for example and without
limitation, to the assembly.
[0006] In some embodiments, the vehicle a/c compressor assembly for
a hybrid or electric vehicle may include a motor housing; an AC
motor in the motor housing; a motor shaft drivingly engaged by the
AC motor and extending from the motor housing; a motor pulley
carried by the motor shaft; a compressor housing; a compressor in
the compressor housing; a compressor shaft drivingly engaging the
compressor and extending from the compressor housing; a compressor
pulley carried by the compressor shaft; a connecting conduit
establishing fluid communication between the motor housing and the
compressor housing; and a drive belt drivingly coupling the
compressor pulley to the motor pulley exterior to the compressor
housing and the motor housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The disclosure will now be made, by way of example, with
reference to the accompanying drawings, in which:
[0008] FIG. 1 is a block diagram of an illustrative embodiment of
the vehicle a/c compressor assembly.
[0009] FIG. 1A is a block diagram of an alternative illustrative
embodiment of the a/c compressor assembly.
[0010] FIG. 2 is a block diagram of another alternative
illustrative embodiment of the a/c compressor assembly.
[0011] FIG. 3 is a block diagram of still another alternative
illustrative embodiment of the a/c compressor assembly.
DETAILED DESCRIPTION
[0012] The following detailed description is merely exemplary in
nature and is not intended to limit the described embodiments or
the application and uses of the described embodiments. As used
herein, the word "exemplary" or "illustrative" means "serving as an
example, instance, or illustration." Any implementation described
herein as "exemplary" or "illustrative" is not necessarily to be
construed as preferred or advantageous over other implementations.
All of the implementations described below are exemplary
implementations provided to enable persons skilled in the art to
practice the disclosure and are not intended to limit the scope of
the appended claims. Furthermore, there is no intention to be bound
by any expressed or implied theory presented in the preceding
technical field, background, brief summary or the following
detailed description.
[0013] Referring initially to FIG. 1, an illustrative embodiment of
the vehicle a/c compressor assembly, hereinafter assembly, is
generally indicated by reference numeral 100. The assembly 100 may
include a motor housing 102. An AC motor 103 may be contained in
the motor housing 102. In some embodiments, the AC motor 103 may be
a variable-speed high-voltage AC motor, or a high-powered motor
having an operating voltage of about 42V-400V (300V nominal) and a
peak of about 4.about.7 kW. A motor shaft 108 may be drivingly
engaged by the AC motor 103. The motor shaft 108 may extend from
the motor housing 102 through a shaft opening (not shown).
[0014] A compressor housing 112 may be generally adjacent and
spaced-apart with respect to the motor housing 102. The compressor
housing 112 may have a housing inlet 113 and a housing outlet 114.
A compressor 115 may be contained in the compressor housing 112. In
some embodiments, the compressor 115 may be a conventional,
mechanically-driven (via FEAD belt) automotive a/c compressor. A
compressor shaft 117 may drivingly engage the compressor 115. The
compressor shaft 117 may extend from the compressor housing 112
through a shaft opening (not shown). The compressor shaft 117 may
be disposed in generally aligned or registering relationship with
respect to the motor shaft 108. A shaft coupler 109 may couple the
motor shaft 108 of the AC motor 103 to the compressor shaft 117 of
the compressor 115 exterior to and generally between the motor
housing 102 and the compressor housing 112.
[0015] The assembly 100 may be mounted to an engine (not shown),
frame or other structural element of an HEV or electric vehicle. In
operation of the assembly 100, the AC motor 103 drives the
compressor 115 through the motor shaft 108, the shaft coupler 109
and the compressor shaft 117. Refrigerant 116 which contains
thermal energy resulting from the heat exchange process in the
vehicle a/c system is distributed through the housing inlet 113,
the compressor 115 and the housing outlet 114, respectively. The
compressor 115 compresses the refrigerant 116, which leaves the
compressor housing 112 through the housing outlet 114 to perform
the heat exchange functions of the vehicle a/c system typically in
the conventional manner. A start-up strategy for the AC motor 103
may be needed to detect a locked-up compressor 115 or to detect a
refrigerant slugging event and slowly bring the compressor 115 up
to speed.
[0016] In the event that the AC motor 103 of the system 100
requires replacement, such as may be required after a prolonged
period of operation of the assembly 100, the motor shaft 108 can be
uncoupled from the compressor shaft 117 at the shaft coupler 109.
The AC motor 103 can be discarded with the motor housing 102.
Alternatively, the AC motor 103 can be recycled or repaired for
subsequent installation and operation in the same or a different
system 100. The motor shaft 108 of a replacement AC motor 103
inside a motor housing 102 can be coupled to the compressor shaft
117 at the shaft coupler 109 for continued operation of the system
100.
[0017] In the event that the compressor 115 of the system 100
requires replacement, the compressor shaft 117 can be uncoupled
from the motor shaft 108 at the shaft coupler 109. The compressor
115 can be discarded with the compressor housing 112.
Alternatively, the compressor 115 may be recycled or repaired for
subsequent installation and operation in the same or a different
system 100. The compressor shaft 117 of a replacement compressor
115 inside a compressor housing 112 can be coupled to the motor
shaft 108 at the shaft coupler 109 for continued operation of the
system 100. It will be appreciated by those skilled in the art that
the AC motor 103 and the compressor 115 can be each selectively
replaced independently of the other in the system 100. This may
provide substantial savings in maintenance costs to an owner or
operator of the vehicle in which the system 100 is installed.
[0018] Referring next to FIG. 1A, an alternative illustrative
embodiment of the vehicle a/c compressor assembly is generally
indicated by reference numeral 100a. The assembly 100a may have a
design which is similar to that of the assembly 100 which was
heretofore described with respect to FIG. 1. In the assembly 100a,
a connecting conduit 122 may connect the housing inlet 113 of the
compressor housing 112 to the motor housing 102. At least one
cooling plate 123 may be provided inside the motor housing 102.
Accordingly, operation of the assembly 100a may be as was
heretofore described with respect to the assembly 100 in FIG. 1
except in the assembly 100a, refrigerant 116 may be distributed
from the A/C system suction line (not shown) to the motor housing
inlet 110 and the connecting conduit 122, respectively, into the
compressor housing 115. As it flows through the motor housing 102,
the cooling plate 123 uses the refrigerant 116 to cool the
electrical components of the AC motor 103. The refrigerant 116 is
discharged from the compressor housing 112 through a refrigerant
outlet 114.
[0019] Referring next to FIG. 2, another alternative illustrative
embodiment of the vehicle a/c compressor assembly is generally
indicated by reference numeral 200. The elements of the system 200
which correspond to the same elements of the system 100 are
designated by the same numerals in the 200 series rather than the
100 series. The system 200 may include a motor housing 202 which
may contain an AC motor 203. In some embodiments, the AC motor 203
may be a high-voltage AC motor, or a high-powered motor having an
operating voltage of about 42V-400V and a peak of about 4.about.7
kW. The AC motor 203 may drivingly engage a motor shaft 208 which
extends from the motor housing 202 through a shaft opening (not
shown). A motor pulley 204 may be drivingly engaged by the motor
shaft 208 outside the motor housing 202.
[0020] A compressor housing 212 may be generally adjacent to the
motor housing 202. The compressor housing 212 may have a housing
inlet 213 and a housing outlet 214. A compressor 215 may be
contained in the compressor housing 212. In some embodiments, the
compressor 215 may be a conventional, mechanically-driven (via FEAD
belt) automotive a/c compressor. A compressor shaft 217 may
drivingly engage the compressor 215. The compressor shaft 217 may
extend from the compressor housing 212 through a shaft opening (not
shown).
[0021] The compressor shaft 217 may be disposed in generally
parallel relationship with respect to the motor shaft 208. A
compressor pulley 205 may drivingly engage the compressor shaft 217
outside the compressor housing 212. A drive belt 206 may be trained
around the motor pulley 204 and the compressor pulley 205. The
drive belt 206 may be a FEAD (Front End Accessory Drive) style
belt. In some embodiments, a drive belt tensioner 207 may engage
the drive belt 206 to selectively tension the drive belt 206
between the motor pulley 204 and the compressor pulley 205.
[0022] The motor housing 202 and the compressor housing 212 may be
mounted to an engine (not shown), frame or other structural element
of an HEV or electric vehicle. In operation of the assembly 200,
responsive to operation of the AC motor 203, the drive belt 206
transmits rotation from the motor pulley 204 to the compression
pulley 205 and the compressor pulley 205 drives the compressor 215
through the compressor shaft 217. Refrigerant 216 which contains
thermal energy resulting from the heat exchange process in the
vehicle a/c system is distributed through the housing inlet 213,
the compressor 215 and the housing outlet 214, respectively. The
compressor 215 compresses the refrigerant 216, which leaves the
compressor 215 through the housing outlet 214 to perform the heat
exchange functions of the vehicle a/c system typically in the
conventional manner. A start-up strategy for the AC motor 203 may
be needed to detect a locked-up compressor 215 or to detect a
refrigerant slugging event and slowly bring the compressor 115 up
to speed.
[0023] In the event that the AC motor 203 requires replacement, the
motor pulley 204 can be uncoupled from the compressor pulley 205 by
removal of the drive belt 206. The motor housing 202 can be
detached from the engine or other structural element of the vehicle
and the AC motor 203 discarded with the motor housing 202.
Alternatively, the AC motor 203 can be recycled or repaired for
subsequent installation and operation in the same or a different
system 200. A motor housing 202 which contains a replacement AC
motor 203 can be attached to the engine or other structural element
of the vehicle. The motor shaft 208 of the replacement AC motor 203
can be coupled to the compressor pulley 205 on the compressor shaft
217 by replacing the drive belt 206 on the motor pulley 204 of the
replacement AC motor 203 and the compressor pulley 205 for
continued operation of the system 200.
[0024] In the event that the compressor 215 requires replacement,
the compressor pulley 205 can be uncoupled from the motor pulley
204 by removal of the drive belt 206. The compressor 215 can be
discarded with the compressor housing 212. Alternatively, the
compressor 215 may be recycled or repaired for subsequent
installation and operation in the same or a different system 200. A
compressor housing 212 which contains a replacement compressor 215
can be attached to the engine or other structural element of the
vehicle. The compressor pulley 205 on the compressor shaft 217 of
the replacement compressor 215 can be coupled to the motor pulley
204 on the motor shaft 208 of the AC motor 203 by replacing the
drive belt 206 on the motor pulley 204 and the compressor pulley
205 for continued operation of the system 200. It will be
appreciated by those skilled in the art that the AC motor 203 and
the compressor 215 can be each selectively replaced independently
of the other in the system 200 to provide substantial savings in
maintenance costs to an owner or operator of the vehicle in which
the system 200 is installed.
[0025] In some applications, the motor housing 202 of the system
200 may be mounted to an engine (not illustrated) of the HEV or
electric vehicle in place of an alternator (not shown) or power
steering pump (not shown). The compressor housing 212 of the system
200 may be mounted to the engine generally adjacent to the motor
housing 202. This application may eliminate the clutch and coil
(not shown) and use the direct drive provided by the motor pulley
204, the drive belt 206 and the compressor pulley 205 to save cost
and weight over the typically increased cost and weight of the
non-hybrid a/c compressor 215 relative to a hybrid vehicle a/c
compressor. In other applications, the clutch and coil may be left
in place and used as an escape mechanism to disconnect the drive in
the event that the a/c compressor 215 seizes, preventing a snapped
or damaged drive belt 206 in the event that the electric motor is
still running.
[0026] Referring next to FIG. 3, another alternative illustrative
embodiment of the vehicle a/c compressor assembly is generally
indicated by reference numeral 300. The assembly 300 may have a
design which is similar to the system 200 which was heretofore
described with respect to FIG. 2. The elements of the system 300
which correspond to the same elements of the system 200 are
designated by the same numerals in the 300 series rather than the
200 series. In the system 300, the motor housing 302 may have a
motor housing inlet 320 and a motor housing outlet 321. The motor
housing inlet 320 may be disposed in fluid communication with the
supply of refrigerant 316. A connecting conduit 322 may connect the
motor housing outlet 321 of the motor housing 302 to the housing
inlet 313 of the compressor housing 312. In some embodiments, at
least one cooling plate 323 may be disposed inside the motor
housing 302 to cool the electronics of the AC motor 303.
[0027] In operation of the system 300, which may be generally as
was heretofore described with respect to operation of the system
200 in FIG. 2, refrigerant 316 may flow through the motor housing
302, the connecting conduit 322, the housing inlet 313 and the
compressor 315. The compressor 315 compresses the refrigerant 316,
which leaves the compressor 315 through the housing outlet 314 to
perform the heat exchange functions of the vehicle a/c system
typically in the conventional manner. As it flows through the motor
housing 302, the refrigerant 316 cools the AC motor 303. In some
alternative embodiments, coolant (not shown) may be supplied to the
AC motor 303 from a low-temperature radiator circuit (not
shown).
[0028] In the system 300, the AC motor 303 may be rated to meet the
maximum load torque of the compressor 303, especially if a
larger-displacement compressor 315 is used. Motor/compressor
combinations which are suitable for the system 300 may include a
variable speed AC motor 303 and a fixed displacement compressor
315, a fixed speed AC motor 303 and a variable displacement
compressor 315 and a variable speed AC motor 303 and a variable
displacement compressor 303. A variable speed AC motor 303 may have
a series of speeds defined, which may be a large number or a small
number (such as 160 or 6 speeds, for example). Another aspect of
matching the AC motor 303 to the compressor 315 may include setting
the range of cooling capacity (both minimum and maximum levels)
which is needed.
[0029] Although the embodiments of this disclosure have been
described with respect to certain exemplary embodiments, it is to
be understood that the specific embodiments are for purposes of
illustration and not limitation, as other variations will occur to
those of skill in the art.
* * * * *