Systems and methods for controlling a vehicle HVAC system

• US 10,675,948 B2
• Filed: 02/22/2017
• Issued: 06/09/2020
• Est. Priority Date: 09/29/2016
• Status: Active Grant

• Current Assignee: Bergstrom Incorporated
• Original Assignee: Bergstrom Incorporated
• Inventors: Connell, Brett S., Herrmann, Brett, Sullivan, Aaron D., Zeigler, Terry
• Primary Examiner(s): Tanenbaum, Steve S
• Application Number:
  US15/439,865
• Publication Number:
  US 20180086181A1
• Time in Patent Office: 1,203 Days
• Field of Search: 62230
• CPC Class Codes: B60H 1/00657 Remote control devices
• CPC Class Codes: B60H 1/00742 by detection of the vehicle occupants' presence; by detection of conditions relating to the body of occupants, e.g. using radiant heat detectors
• CPC Class Codes: B60H 1/00778 the input being a stationary vehicle position, e.g. parking or stopping
• CPC Class Codes: B60H 1/00985 Control systems or circuits characterised by display or indicating devices, e.g. voice simulators characterised by the input of sound using a voice synthesizer B60H1/00757; B60H1/00978 takes precedence
• CPC Class Codes: B60H 1/3208 Vehicle drive related control of the compressor drive means, e.g. for fuel saving purposes
• CPC Class Codes: B60H 1/323 characterised by comprising auxiliary or multiple systems, e.g. plurality of evaporators, or by involving auxiliary cooling devices
• CPC Class Codes: B60H 2001/3261 of the air at an evaporating unit
• CPC Class Codes: B60H 2001/3272 to control the revolving speed of a compressor
• CPC Class Codes: B60H 2001/3273 related to the operation of the vehicle, e.g. the compressor driving torque
• CPC Class Codes: B60H 2001/3277 to control the air flow
• CPC Class Codes: B60H 2001/3282 to control the air flow
• CPC Class Codes: B60H 2001/3294 Compressor drive is hybrid

Abstract

Disclosed are climate systems for vehicles and methods for controlling the climate systems. In some implementations, a climate system includes: (1) a temperature sensor configured to measure a temperature within the compartment of the vehicle; (2) a user interface configured to receive a desired temperature from a user; (3) a first compressor powered by an engine of the vehicle to compress a refrigerant; (4) a second compressor driven by an electric motor to compress the refrigerant; and (5) a controller electrically coupled to the first compressor and the second compressor. The controller configured to: (1) calculate a thermal load of the compartment based on a difference between a desired temperature and a measured temperature; and, (2) based on the calculated load, selectively activate: (i) the engine, (ii) the first compressor, and/or (iii) the second compressor.

Claims

1. A climate system for conditioning a compartment of a vehicle, comprising:

a temperature sensor configured to measure a temperature within the compartment of the vehicle;

a user interface configured to receive a desired temperature of the compartment from a user;

a first compressor powered by an engine of the vehicle to compress a refrigerant while the engine of the vehicle is on;

a second compressor driven by an electric motor to compress the refrigerant; and

a controller electrically coupled to the first compressor and the second compressor, and configured to;

obtain the desired temperature of the compartment from the user interface;

obtain the measured temperature of the compartment from the temperature sensor;

calculate a thermal load of the compartment based at least partially on a difference between the desired temperature and the measured temperature;

upon determining that the thermal load exceeds a first predetermined thermal load threshold;

in accordance with a determination that the engine is off, turn on the engine;

in accordance with a determination that the first compressor is off, activate the first compressor to compress the refrigerant for cooling the compartment; and

in accordance with a determination that the second compressor is off, activate the second compressor to compress the refrigerant for cooling the compartment;

upon determining that the thermal load does not exceed the first predetermined thermal load threshold but does exceed a second thermal load threshold lower than the first predetermined thermal load threshold;

in accordance with a determination that the engine is off, turn on the engine; and

in accordance with a determination that the first compressor is off, activate the first compressor to compress the refrigerant for cooling the compartment; and

upon determining that the thermal load does not exceed the second predetermined thermal load threshold;

in accordance with a determination that the first compressor is on, deactivate the first compressor; and

in accordance with a determination that the second compressor is off, activate the second compressor to compress the refrigerant for cooling the compartment.

2. The climate system of claim 1, wherein the second compressor is fluidly coupled in parallel with the first compressor, and fluidly coupled in series with a first condenser and a first evaporator.

3. The climate system of claim 1, further comprising an object sensor configured to sense a temperature-sensitive object in the vehicle;

wherein the controller is configured to automatically activate in accordance with a determination that the temperature-sensitive object is in the vehicle.

4. The climate system of claim 1, wherein upon determining that the thermal load does not exceed the first predetermined thermal load threshold but does exceed the second thermal load threshold, the controller is configured to automatically activate the second compressor, in accordance with a determination that the second compressor is off, to compress the refrigerant, thereby reducing load on the first compressor.

5. The climate system of claim 1, wherein the controller is configured to:

after activating the first compressor, automatically deactivate the first compressor while maintaining activation of the second compressor, in accordance with a determination that the thermal load of the compartment does not exceed the second predetermined thermal load threshold; and

automatically deactivate both the first compressor and the second compressor, in accordance with a determination that the temperature of the compartment does not exceed the desired temperature.

6. The climate system of claim 1, further comprising:

a heat exchanger thermally coupled with the compartment of the vehicle; and

a coolant pump connected to an engine coolant line for circulating a heated engine coolant from the engine to the heat exchanger to heat the compartment of the vehicle;

wherein the controller is configured to automatically activate the coolant pump in accordance with a determination that the temperature in the compartment does not exceed the desired temperature and that the engine is turned on.

7. The climate system of claim 1, further comprising:

a first flow control valve disposed upstream of the first compressor and configured to selectively permit flow of the refrigerant to the first compressor; and

a second flow control valve disposed upstream of the second compressor and configured to selectively permit flow of the refrigerant to the second compressor.

8. The climate system of claim 1, further comprising a second condenser disposed downstream of the second compressor and fluidly coupled to the second compressor to condense the refrigerant compressed by the second compressor;

wherein the second compressor and the second condenser form an auxiliary unit fluidly coupled in parallel with the first compressor and fluidly coupled in series with a first condenser and a first evaporator.

9. The climate system of claim 8, further comprising:

a first air blower electrically coupled to the controller, positioned proximate the second condenser and configured to blow ambient air or air from an air intake of the engine over the second condenser;

a second air blower electrically coupled to the controller, positioned proximate the first condenser and configured to blow the ambient air or air from the air intake of the engine over the first condenser; and

a third air blower electrically coupled to the controller, positioned proximate the first evaporator and configured to blow the ambient air or air from the air intake of the engine over the first evaporator;

wherein the controller is configured to;

automatically concurrently activate the first air blower and the second condenser, automatically concurrently activate the second air blower and the first condenser, and automatically concurrently activate the third air blower and the first evaporator.

10. A method for controlling a climate system installed in a vehicle, the method comprising:

obtaining a desired temperature of a compartment of the vehicle from a user interface configured to receive the desired temperature of the compartment from a user;

obtaining a measured temperature of the compartment from a temperature sensor;

calculating a thermal load of the compartment based at least partially on a difference between the desired temperature and the measured temperature;

upon determining that the thermal load exceeds a first predetermined thermal load threshold;

in accordance with a determination that an engine of the vehicle is off, turn on the engine;

in accordance with a determination that a first compressor is off, activate the first compressor to compress a refrigerant for cooling the compartment, wherein the first compressor comprises an engine-driven compressor; and

in accordance with a determination that a second compressor driven by an electric motor is off, activate the second compressor to compress the refrigerant for cooling the compartment;

upon determining that the thermal load does not exceed the first predetermined thermal load threshold but does exceed a second thermal load threshold lower than the first predetermined thermal load threshold;

in accordance with a determination that the engine is off, turn on the engine; and

in accordance with a determination that the first compressor is off, activate the first compressor to compress the refrigerant for cooling the compartment; and

upon determining that the thermal load does not exceed the second predetermined thermal load threshold;

in accordance with a determination that the first compressor is on, deactivate the first compressor; and

in accordance with a determination that the second compressor is off, activate the second compressor to compress the refrigerant for cooling the compartment.

11. The method of claim 10, further comprising, upon determining that the thermal load does not exceed the first predetermined thermal load threshold but does exceed the second thermal load threshold, activating the second compressor in accordance with a determination that the second compressor is off to compress the refrigerant, thereby reducing load on the first compressor.

12. The method of claim 10, wherein the climate system further comprises a heat exchanger thermally coupled to the compartment, and a coolant pump connected to an engine coolant line for circulating a heated engine coolant from the engine to the heat exchanger;

and

the method further comprises, in accordance with a determination that the temperature in the compartment does not exceed the desired temperature and in accordance with a determination that the engine is on, automatically activating the coolant pump to direct the heated engine coolant from the engine to the heat exchanger to heat the compartment of the vehicle.

13. The method of claim 10, further comprising:

dynamically monitoring the thermal load of the compartment; and

automatically deactivating the first compressor, while maintaining activation of the second compressor, in accordance with a determination that the thermal load does not exceed the second predetermined thermal load threshold.

14. The method of claim 10, further comprising:

dynamically monitoring the temperature of the compartment; and

automatically deactivating both the first compressor and the second compressor in accordance with a determination that the temperature of the compartment does not exceed the desired temperature.

15. The method of claim 10, wherein the controller is wirelessly coupled to a mobile remote control configured to selectively activate and deactivate the controller from inside and outside of the vehicle, and the method further comprises selectively activating and deactivating the controller via the mobile remote control.

16. The method of claim 10, wherein calculating the thermal load of the compartment comprises calculating the thermal load of the compartment based at least partially on the measured temperature of the compartment, the desired temperature of the compartment, a measured ambient temperature outside the vehicle, a size of the compartment, and a shape of the compartment.

17. The method of claim 15, further comprising automatically activating the controller in accordance with a determination that the remote control is moving towards the vehicle and is within a predetermined distance from the vehicle.

18. The method of claim 15, further comprising automatically deactivating the controller in accordance with a determination that the remote control is moving away from the vehicle and is beyond a predetermined distance from the vehicle.

19. The method of claim 10, further comprising, prior to calculating the thermal load of the compartment, in accordance with a determination that the measured temperature is outside of a desired temperature range, notifying the user of one or more of the following:

the measured temperature;

an outside temperature;

a temperature difference between the measured temperature and the desired temperature range; and

a temperature difference between the outside temperature and the desired temperature range.

20. The method of claim 19, further comprising:

obtaining instructions from the user as to whether to perform cooling or heating; and

operating one or more of the following in accordance with the obtained instructions;

the engine;

the first compressor;

the second compressor; and

a coolant pump.

21. The method of claim 10, wherein the climate system further comprises an object sensor configured to sense a temperature-sensitive object in the vehicle, and the method further comprises automatically activating the climate system in accordance with a determination that the temperature-sensitive object is in the vehicle.

22. The method of claim 21, further comprising, prior to calculating the thermal load of the compartment, in accordance with a determination that the measured temperature is outside of a desired temperature range and that the temperature-sensitive object is in the vehicle, notifying the user of the presence of the temperature-sensitive object.