Method and auxiliary system for operating a comfort subsystem for a vehicle

• US 7,543,454 B2
• Filed: 03/14/2006
• Issued: 06/09/2009
• Est. Priority Date: 03/14/2005
• Status: Active Grant

• Current Assignee: Anthony England, Clean Emissions Technologies, Inc., Fuel Cell Idling Systems, Inc., Rick Akin
• Original Assignee: ZERO Tension Systems LLC
• Inventors: Harris, Warner Olan
• Primary Examiner(s): Tapolcai; William E
• Application Number:
  US11/374,709
• Publication Number:
  US 20060207274A1
• Time in Patent Office: 1,183 Days
• Field of Search: 622/36, 62239-244, 621/15, 417/362, 464/178, 464/184
• US Class Current: 62/115
• CPC Class Codes: B60H 1/00535 Mounting or fastening of the housing to the vehicle
• CPC Class Codes: B60H 1/00542 Modular assemblies
• CPC Class Codes: B60H 1/3222 characterised by the compressor driving arrangements, e.g. clutches, transmissions or multiple drives B60H1/3208, B60H1/3226 take precedence
• CPC Class Codes: Y10T 29/53 Means to assemble or disassemble

Abstract

According to one form of the invention, an auxiliary system is provided for supplying air conditioning to the cabin of a truck. The system includes an air conditioning compressor having a jackshaft mounted on a hub of the compressor. The system further includes an electric motor connected to the jackshaft by a belt for the motor, wherein the electric motor has a drive shaft and a pulley rigidly secured thereon, i.e., with no clutch and with no provision for slippage of the pulley relative to the drive shaft. The jackshaft has a pulley thereon for the electric motor drive. An end of the jackshaft that is not proximate to the compressor is rotatably held by a bearing and a bearing bracket in order to increase capability of the jackshaft to withstand side loading.

Claims

1. An air conditioning system for a cabin of a vehicle comprising:

an air conditioning compressor having a drive shaft with a hub that is rotated to operate the air conditioning compressor;

an electrically operated clutch for coupling a first pulley to the drive shaft of the air conditioning compressor in response to control signals, the first pulley rotated by a first belt coupled to a drive engine of the vehicle;

a jackshaft rigidly coupled to the hub of the air conditioning compressor; and

a second pulley rigidly coupled to the jackshaft and driven by an electric motor with a second drive belt, wherein an end of the jackshaft not coupled to the hub is rotatably coupled with a bearing to a bearing bracket to reduce side loading on the jackshaft from the second drive belt.

2. The system of claim 1, further comprising an auxiliary controller generating the control signals in response to vehicle cabin controls.

3. The system of claim 2, wherein the auxiliary controller generates a control signal that disengages the clutch when the electric motor is powered and driving the jackshaft via the second drive belt.

4. The system of claim 2, wherein the electric motor is powered by a fuel cell system generating a fuel cell DC voltage.

5. The system of claim 4, wherein the electric motor is a 3-phase AC motor powered by a 3-phase AC voltage.

6. The system of claim 5, further comprising a DC to AC converter system having an input coupled to an output of the fuel cell system and generating the 3-phase AC voltage for the electric motor in response to control signals from the auxiliary controller.

7. The system of claim 6, further comprising a buffer battery having a battery output coupled with a diode to the input of the DC to AC converter system, wherein the buffer battery is charged by the fuel cell system when its charge is low and assists the fuel cell system in supplying power when it is charged and a DC output of the fuel cell system is low.

8. The system of claim 6, further comprising an auxiliary fan for cooling a condenser of the air conditioning system when the vehicle engine is not running, the auxiliary fan powered from a DC voltage in the DC to AC converter system in response to the control signals from the auxiliary controller.

9. The system of claim 6, wherein a fuel cell in the fuel cell system is a hydrogen fuel cell coupled to a source of pressurized hydrogen and a source of pressurized air.

10. The system of claim 9, wherein the source of pressurized air is supplied by a blower powered by the fuel cell.

11. The system of claim 9, wherein the source of pressurized air is supplied from an external pressurized air source when the fuel cell is in a start-up mode.

12. The system of claim 11, wherein the external pressurized air source is a pressurized tire of the vehicle.

13. The system of claim 4, wherein a starting battery of the vehicle is charged by the fuel cell system when the starting battery is discharged or is at a low charge state.

14. The system of claim 9, wherein the fuel cell system includes the DC to AC converter, the auxiliary controller, the fuel cell, a blower, a buffer battery, and the source of pressurized hydrogen.

15. The system of claim 14, wherein the fuel cell system is mounted to a chassis of the vehicle and mechanically coupled to the jackshaft of the air compressor with the second drive belt and electrically coupled to the auxiliary fan and cabin controls of the vehicle.

16. The system of claim 11, further comprising circuitry tor starting the vehicle by supplying the fuel cell system with the external source of pressurized air.

17. The system of claim 10, wherein the blower is electrically coupled to an output of the fuel cell and operated at a reduced blower speed in response to control signals from the auxiliary controller when a fuel cell DC voltage reaches a first value, and the blower speed is increased when the fuel cell DC voltage reaches a second value greater than the first value.

18. The system of claim 16, wherein the AC motor is configured as a generator when the vehicle drive engine is running thereby generating a source of AC power.

19. The system of claim 12, wherein the pressurized tire of the vehicle is coupled to the fuel cell system using a hose with a standard valve stem connector.

20. An auxiliary system for a vehicle comprising:

a hydrogen fuel cell receiving a regulated flow of pressurized hydrogen, pressurized air and generating a DC voltage output;

a DC to AC converter receiving the DC voltage output and generating 3-phase AC output voltages;

an electric motor coupled to the 3-phase AC output voltages and having an output shaft coupled with a drive belt to a jackshaft coupled to a hub of a compressor of an air conditioning system of the vehicle;

a controller receiving the DC voltage output and generating a charge voltage for a starter battery of the vehicle and a fan drive voltage; and

an auxiliary fan coupled to the fan drive voltage and generating an air stream directed to a condenser for the air conditioning system of the vehicle, wherein the hydrogen fuel cell, a source of pressurized hydrogen, the DC to AC converter, the electric motor and the controller are in a system module.

21. The system as recited in claim 20, wherein the system module is mounted to a chassis of the vehicle using air shock mounts.

22. An air conditioning system for a vehicle comprising:

a condenser for the air conditioning system normally cooled in response to air flow from fan blades coupled to a drive engine of the vehicle;

an auxiliary fan receiving an auxiliary fan voltage and directing an auxiliary air flow to the condenser;

a compressor for the air conditioning system having a drive shaft coupled to a first pulley with an electrically operated clutch, the first pulley coupled with a first drive belt to the drive engine of the vehicle;

a jackshaft connected to a hub on the drive shaft of the compressor, wherein an end of the jackshaft is rotatably coupled to a bearing attached to a bearing plate;

an auxiliary AC electric motor having a drive shaft rigidly coupled to a second pulley, the second pulley coupled with a second drive belt to the jackshaft, wherein the drive engine rotates the compressor and the electric motor when an electric operated clutch is engaged and the electric motor rotates the compressor when the electric operated clutch is disengaged;

a fuel cell system receiving pressurized hydrogen and a stream of pressurized air and generating a DC output voltage;

a controller receiving the DC output voltage and cabin controls and generating the auxiliary fan voltage and a converter output;

a DC to AC converter receiving the converter output and generating an AC voltage for the auxiliary AC electric motor.

23. The system of claim 22, wherein the fuel cell system comprises:

a hydrogen fuel cell;

a pressurized tank of hydrogen coupled to the hydrogen fuel cell;

a blower for supplying the stream of pressurized air to the hydrogen fuel cell;

a fuel cell controller receiving a voltage output from the hydrogen fuel cell, cabin controls, and generating the DC output voltage and a voltage to power the blower; and

a DC to DC converter receiving the DC voltage output from the fuel cell controller and generating a charge voltage for a starter battery of the vehicle.

24. The system of claim 23, wherein the stream of pressurized air is supplied from and external source such as an air compressor or a pressurized tire of the truck.

25. The system of claim 22, wherein the AC electric motor is operated as a generator when the drive engine rotates the AC electric motor when the electric operated clutch is engaged.

26. A truck comprising:

a cabin for a driver;

a chassis configured to couple to a trailer or a load carrying bed; and

an air conditioning system for the cabin of the truck having a condenser for the air conditioning system normally cooled in response to air flow from fan blades coupled to a drive engine of the truck, an auxiliary fan receiving an auxiliary fan voltage and directing an auxiliary air flow to the condenser, a compressor for the air conditioning system having a drive shaft coupled to a first pulley with an electrically operated clutch, the first pulley coupled with a first drive belt to the drive engine of the truck, a jackshaft directly coupled to a hub on the drive shaft of the compressor, wherein an end of the jackshaft is rotatably coupled to a bearing attached to a bearing plate, an auxiliary AC electric motor having a drive shaft rigidly coupled to a second pulley, the second pulley coupled with a second drive belt to the jackshaft, wherein the drive engine rotates the compressor and the electric motor when an electric operated clutch is engaged and the electric motor rotates the compressor when the electric operated clutch is disengaged, a fuel cell system receiving pressurized hydrogen and a stream of pressurized air and generating a DC output voltage, a controller receiving the DC output voltage and cabin controls and generating the auxiliary fan voltage and a converter output, and a DC to AC converter receiving the converter output and generating an AC voltage for the auxiliary AC electric motor.

27. The system of claim 26, wherein the fuel cell system comprises:

a hydrogen fuel cell;

a pressurized tank of hydrogen coupled to the hydrogen fuel cell;

a blower for supplying the stream of pressurized air to the hydrogen fuel cell;

a fuel cell controller receiving a voltage output from the hydrogen fuel cell, cabin controls, and generating the DC output voltage and a voltage to power the blower; and

a DC to DC converter receiving the DC voltage output from the fuel cell controller and generating a charge voltage fur a starter battery of the truck.

28. The system of claim 27, wherein the stream of pressurized air is supplied from an external source such as an air compressor or a pressurized tire of the truck.

29. The system of claim 26, wherein the AC electric motor is operated as a generator when the drive engine rotates the electric motor when the electric operated clutch is engaged.

30. A method for operating an air conditioning system for a cabin of a vehicle driven by an internal combustion engine (ICE), wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the drive shaft of the air conditioning compressor coupled to a first pulley with an electrically operated clutch responsive to control signals, the first pulley rotated by a first belt coupled to the ICE, a jackshaft rigidly coupled to the hub of the air conditioning compressor, a second pulley rigidly coupled to the jackshaft, and an electric motor coupled to the second pulley with a second drive belt, wherein an end of the jackshaft not coupled to the hub rotatably with a bearing is coupled to a bearing bracket to reduce side loading on the jackshaft from the second drive belt. the method comprising:

responsive to the control signals, driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source comprises a battery based power source having series and parallel connected battery cells configured to generate a battery DC voltage.

31. The method of claim 30 further comprising generating the control signals with an auxiliary controller in response to cabin controls in the vehicle.

32. The method of claim 31, wherein the auxiliary controller generates a control signal that signals the clutch to disengage the first pulley from the drive shaft of the air conditioning compressor when the electric motor is powered and driving the jackshaft via the second drive belt.

33. The method of claim 30, wherein the auxiliary power source further comprises a fuel cell with an output that generates a fuel cell DC voltage.

34. The method of claim 32, wherein the electric motor is an AC motor.

35. The method of claim 34, further comprising a DC to AC converter system receiving DC power from the auxiliary power source and generating the AC voltage for driving the AC motor in response to control signals from the auxiliary controller.

36. The method of claim 31, further comprising an auxiliary fan for cooling a condenser of the air conditioning system when the ICE is not running, wherein the auxiliary fan is powered in response to the controls signals from the auxiliary controller.

37. A method for operating an air conditioning system for a cabin of a vehicle driven by an internal combustion engine (ICE), wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the drive shaft of the air conditioning compressor coupled to a first pulley with an electrically operated clutch responsive to control signals, the first pulley rotated by a first belt coupled to the ICE, a jackshaft rigidly coupled to the hub of the air conditioning compressor, a second pulley rigidly coupled to the jackshaft, and an electric motor coupled to the second pulley with a second drive belt, the method comprising:

responsive to the control signals, driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source comprises a battery based power source having series and parallel connected battery cells configured to generate a battery DC voltage;

supplying power from the fuel cell DC voltage when the battery DC voltage is below a predetermined low battery value;

charging the battery based power source from the fuel cell DC voltage while providing power when the battery DC voltage is below the predetermined low battery value;

supplying power from both the fuel cell DC voltage and the battery DC voltage in parallel, wherein the battery DC voltage provides a peak current requirement; and

supplying power from the battery based power source when the fuel cell DC voltage is below a predetermined low fuel cell value.

38. A method for operating an air conditioning system for a cabin of a vehicle driven by an internal combustion engine (ICE), wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the drive shaft of the air conditioning compressor coupled to a first pulley with an electrically operated clutch responsive to control signals, the first pulley rotated by a first belt coupled to the ICE, a jackshaft rigidly coupled to the hub of the air conditioning compressor, a second pulley rigidly coupled to the jackshaft, and an electric motor coupled to the second pulley with a second drive belt, the method comprising:

responsive to the control signals, driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source comprises a battery based power source having series and parallel connected battery cells configured to generate a battery DC voltage, wherein the auxiliary power source further comprises a fuel cell system with an output that generates a fuel cell DC voltage, wherein a fuel cell in the fuel cell system is a hydrogen fuel cell coupled to a source of pressurized hydrogen and a source of pressurized air.

39. The method of claim 38, wherein the source of pressurized air is supplied by a blower powered by the fuel cell.

40. The method of claim 38, wherein the source of pressurized air is supplied from an external pressurized air source when the fuel cell is in a start-up mode.

41. The method of claim 40, wherein the external pressurized air source is a pressurized tire of the vehicle.

42. The method of claim 39, wherein the auxiliary power source includes the DC to AC converter, the auxiliary controller, the fuel cell, the blower, and the source of pressurized hydrogen.

43. The method of claim 42, further comprising

mounting the auxiliary power source to a chassis of the vehicle;

and

electrically coupling the auxiliary power source to the auxiliary fan and cabin controls of the vehicle.

44. The method of claim 41, further comprising starting the vehicle by supplying the hydrogen fuel cell with the external source of pressurized air in an event that the battery based power source and the starter battery arc in a discharged state.

45. The method of claim 44, wherein the blower is electrically coupled to the fuel cell DC voltage and operated at a reduced blower speed, in response to control signals from the auxiliary controller, when the fuel cell DC voltage reaches a first value and the blower speed is increased when the fuel cell DC voltage reaches a second value greater than the first value.

46. The method of claim 41, wherein a pressurized tire of the vehicle is coupled to the fuel cell system using a hose with a standard valve stem connector.

47. A method for operating an air conditioning system for a cabin of a vehicle driven by an internal combustion engine (ICE), wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the drive shaft of the air conditioning compressor coupled to a first pulley with an electrically operated clutch responsive to control signals, the first pulley rotated by a first belt coupled to the ICE, a jackshaft rigidly coupled to the hub of the air conditioning compressor, a second pulley rigidly coupled to the jackshaft, and an electric motor coupled to the second pulley with a second drive belt, the method comprising:

responsive to the control signals, driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source comprises a battery based power source having series and parallel connected battery cells configured to generate a battery DC voltage, wherein a starting battery of the vehicle is charged by the auxiliary power source when the starting battery is discharged or is at a low charge state.

48. A method for operating an air conditioning system for a cabin of a vehicle driven by an internal combustion engine (ICE), wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the drive shaft of the air conditioning compressor coupled to a first pulley with an electrically operated clutch responsive to control signals, the first pulley rotated by a first belt coupled to the ICE, a jackshaft rigidly coupled to the hub of the air conditioning compressor, a second pulley rigidly coupled to the jackshaft, and an electric motor coupled to the second pulley with a second drive belt, the method comprising:

responsive to the control signals, driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source comprises a battery based power source having series and parallel connected battery cells configured to generate a battery DC voltage;

generating the control signals with an auxiliary controller in response to cabin controls in the vehicle, wherein the auxiliary controller generates a control signal that signals the clutch to disengage the first pulley from the drive shaft of the air conditioning compressor when the electric motor is powered and driving the jackshaft via the second drive belt, wherein the electric motor is an AC motor; and

configuring the AC motor as a generator when the ICE is running and the first pulley is coupled to the drive shaft by the electric operated clutch thereby generating a source of AC power.

49. An air conditioning system comprising:

an air conditioning compressor having a drive shaft with a hub that is rotated to operate the air conditioning compressor;

means for coupling a first pulley to the drive shaft of the air conditioning compressor, the first pulley rotated by a first belt coupled to an internal combustion engine;

means for coupling a second pulley to the drive shaft of the air conditioning compressor, the second pulley rotated by a second belt coupled to an electric motor;

means for disengaging the internal combustion engine from rotating the drive shaft when the electric motor is to rotate the drive shaft; and

an auxiliary fan for cooling a condenser of the air conditioning system when the internal combustion engine is not running, wherein the electric motor is powered by a fuel cell system, wherein a starting battery of the internal combustion engine is charged by the fuel cell system when the starting battery is discharged or is at a low charge state.

50. A method for implementing an air conditioning system for a cabin of an internal combustion engine (ICE) vehicle, wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the method comprising:

coupling a first pulley to the drive shaft of the air conditioning compressor with an electrically operated clutch, the first pulley rotated by a first belt coupled to the ICE of the vehicle;

rigidly coupling a jackshaft to the hub of the air conditioning compressor;

rigidly coupling a second pulley to the jackshaft;

coupling an electric motor to the second pulley with a second drive belt;

coupling an end of the jackshaft not coupled to the hub rotatably with a bearing to a bearing bracket to reduce side loading on the jackshaft from the second drive belt; and

driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source comprises a battery based power source having battery cells configured to generate a battery DC voltage.

51. The method of claim 50, wherein the auxiliary power source further comprises a fuel cell with an output that generates a fuel cell DC voltage.

52. A method for implementing an air conditioning system for a cabin of an internal combustion engine (ICE) vehicle, wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the method comprising:

coupling a first pulley to the drive shaft of the air conditioning compressor with an electrically operated clutch, the first pulley rotated by a first belt coupled to the ICE of the vehicle;

rigidly coupling a jackshaft to the hub of the air conditioning compressor,

rigidly coupling a second pulley to the jackshaft;

coupling an electric motor to the second pulley with a second drive belt;

driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein the auxiliary power source further comprises a fuel cell with an output that generates a fuel cell DC voltage;

supplying power from the fuel cell DC voltage when the battery DC voltage is below a predetermined low battery value;

charging the battery based power source from the fuel cell DC voltage while providing power when the battery DC voltage is below the predetermined low battery value;

supplying power from both the fuel cell DC voltage and the battery DC voltage in parallel, wherein the battery DC voltage provides a peak current requirement; and

supplying power from the battery based power source when the fuel cell DC voltage is below a predetermined low fuel cell value.

53. A method for operating an air conditioning system for a cabin of a vehicle driven by an internal combustion engine (ICE), wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the drive shaft of the air conditioning compressor coupled to a first pulley with an electrically operated clutch responsive to control signals, the first pulley rotated by a first belt coupled to the ICE, a jackshaft rigidly coupled to the hub of the air conditioning compressor, a second pulley rigidly coupled to the jackshaft, and an electric motor coupled to the second pulley with a second drive belt, the method comprising:

responsive to the control signals, driving the electric motor with an auxiliary power source to operate the air conditioning system when the ICE is off and the electrically operated clutch disengages the first pulley from the drive shaft of the air conditioning compressor, wherein an end of the jackshaft not coupled to the hub rotatably with a bearing is coupled to a bearing bracket to reduce side loading on the jackshaft from the second drive belt.

54. A method for implementing an air conditioning system for a cabin of an internal combustion engine (ICE) vehicle, wherein a compressor of the air conditioning system has a drive shaft with a hub that is rotated to operate the compressor, the method comprising:

coupling a first pulley to the drive shaft of the air conditioning compressor with an electrically operated clutch, the first pulley rotated by a first belt coupled to the ICE of the vehicle;

rigidly coupling a jackshaft to the hub of the air conditioning compressor;

rigidly coupling a second pulley to the jackshaft;

coupling an electric motor to the second pulley with a second drive belt; and

coupling an end of the jackshaft not coupled to the hub rotatably with a bearing to a bearing bracket to reduce side loading on the jackshaft from the second drive belt.