Patent Application
20130086932
The present invention relates to a vehicle air-conditioning device, and more specifically, to a technique to diagnose whether or not any refrigerant leakage occurs.
In a heat-pump air-conditioning device, when refrigerant leaks, adverse effects such as performance decrements are caused. In view of this, Patent Document 1 discloses such a technique that refrigerant flow is measured, and when the measured value greatly deviates from a value obtained in a normal condition, it is determined that some refrigerant leakage occurs.
As disclosed in Patent Document 1, in a case of an air-conditioning device which is disposed in a showcase and operated therein normally, it is possible to determine whether or not any refrigerant leakage occurs by setting one threshold value for determination. However, in a case of a vehicle air-conditioning device, since a refrigerant flow varies greatly because of a great change or the like of a rotational speed of an engine for driving a compressor, it has been difficult to precisely determine whether or not any refrigerant leakage occurs, based on one threshold value for determination to be driven, without any restrictions from an operating condition.
The present invention has been achieved in view of such a conventional problem, and an object of the present invention is to precisely diagnose refrigerant leakage in a vehicle air-conditioning device by a simple configuration without any restrictions from an operating condition of the air-conditioning device.
In view of this, the present invention is a vehicle air-conditioning device (a refrigerant leakage diagnosis method thereof) in which a compressor, a condenser, an expansion valve, and an evaporator are connected in a circular manner through refrigerant pipes, and is configured to include the following units (steps):
A. a unit (step) for detecting a refrigerant volume flow in an area in which refrigerant circulates in a liquid state in the vehicle air-conditioning device;
B. a unit (step) for setting a threshold value for determination of refrigerant leakage in a variable manner based on an operating condition of the vehicle air-conditioning device; and
C. a unit (step) for determining that the refrigerant is leaking when the detected refrigerant volume flow exceeds the threshold value for determination of refrigerant leakage.
In a vehicle air-conditioning device, when refrigerant leaks, an amount of refrigerant becomes insufficient and a refrigerant density decreases. This makes it difficult for the refrigerant to condense in a condenser sufficiently and causes gaseous refrigerant to be mixed even in an area such as a condenser downstream in which the refrigerant is in a liquid state when no refrigerant leakage occurs, thereby causing a gas-liquid mixing state. If a volume flow of the refrigerant in such a gas-liquid mixing state including the gaseous refrigerant having a low density is detected by a refrigerant flow detecting unit, the volume flow greatly increases as compared with that volume flow of the refrigerant in a liquid state which is detected in a normal condition.
Furthermore, a flow of the refrigerant in a liquid state in the normal condition also varies depending on an operating condition of the air-conditioning device.
In view of this, with the use of a threshold value for determination of refrigerant leakage which is set to be changeable according to variations of the refrigerant flow caused due to variations of the operating condition, it is possible to precisely determine whether or not any refrigerant leakage occurs, without any restrictions from the operating condition of the air-conditioning device.
The following describes embodiments of the present invention.
The refrigerant circuit is configured such that a variable-capacity compressor 1, a condenser 2, an expansion valve 3, and an evaporator 4 are connected in a circular manner through refrigerant pipes 5.
The variable-capacity compressor 1 drives a valve element for opening and closing communication between a discharge side and an inlet side by controlling an amount of electricity of a capacity control valve 1a provided therein, and controls a discharge capacity (a stroke of a plunger) in a variable manner by adjusting an intake pressure (=inlet pressure Ps) (see, in particular, Japanese Laid-Open Patent Publication No. 2003-301772).
The compressor 1 is driven by an engine (an internal combustion engine) 21, and gaseous refrigerant discharged from the compressor 1 at a high pressure and a high temperature reaches the condenser 2, in which the gaseous refrigerant is cooled down by heat exchange with air stream (external air) passing nearby while having contact with an external surface of the condenser 2, so that the gaseous refrigerant is turned into condensate liquid.
The liquid-state refrigerant flowed out from the condenser 2 is expanded and depressurized by the expansion valve 3, and then reaches the evaporator 4 disposed in the interior of a vehicle. After the liquid-state refrigerant is evaporated and gasified in the evaporator 4 by heat exchange with air circulated and blown in the interior of a vehicle by a fan (not illustrated), the refrigerant is inhaled into the compressor 1 again and compressed
Thus, cooled air is sent into the interior of a vehicle, so that air-conditioning is performed.
In such a vehicle air-conditioning device, a device for diagnosing whether or not any refrigerant leakage occurs is configured as follows.
A volume-flow sensor 6 for detecting a volume flow of the liquid-state refrigerant is disposed in that refrigerant pipe 5 provided between an outlet of the condenser 2 and the expansion valve 3 through which the liquid-state refrigerant flows. This volume-flow sensor 6 includes an orifice 61 provided in series between refrigerant pipes 5 and one pair of pressure sensors 62 and 63 for detecting pressures on an upstream side and a downstream side thereof, and is configured to calculate a volume flow based on the detected pressure values of the upstream side and the downstream side. Any volume-flow sensors such as an impeller type may be usable besides the above one, provided that they can measure a volume flow.
The detected pressure values of the one pair of pressure sensors 62 and 63 are output to an air-conditioning/electronic control unit (hereinafter referred to as the A/C ECU) 22, and the A/C ECU 22 calculates a volume flow Gr of the refrigerant based on the detected pressure values.
In the engine 21, a rotational speed sensor 23 for detecting an engine speed Ne is disposed, and a detected value of the engine speed from the rotational speed sensor 23 is output to an engine control unit (hereinafter referred to as the engine ECU) 24.
The engine ECU 24 performs engine control such as setting a fuel injection amount Ti based on the engine speed Ne and other detected values to output it to a fuel injection device of the engine 21. In the meantime, the engine ECU 24 calculates a compressor rotational speed Nc which is proportional to the engine speed, and outputs it to the A/C ECU 22.
The A/C ECU 22 outputs a controlled current value Iecv to the capacity control valve 1a of the compressor 1 so that a necessary refrigerant flow is obtained based on the calculated refrigerant volume flow Gr and compressor rotational speed Nc.
Furthermore, the A/C ECU 22 calculates a rotation torque Tc of the compressor 1 based on the refrigerant volume flow Gr, the compressor rotational speed Nc, and the like, and outputs a signal of the rotation torque Tc to the engine ECU 24. Hereby, for example, the engine ECU 24 corrects the fuel injection amount of the engine 21 to be increased as the rotation torque Tc of the compressor 1 is greater, thereby increasing an output torque Te of the engine 21 so that rotational variations of the compressor 1 can be suppressed.
Further, the A/C ECU 22 diagnoses whether or not any refrigerant leakage occurs, based on the detected refrigerant volume flow Gr.
After the engine 21 is started (an ignition switch is turned ON) in step S1, it is determined whether or not an air-conditioning switch is turned ON, in step S2.
When it is determined that the air-conditioning switch is turned ON, the process advances to step S3, in which a compressor rotational speed Nc and a controlled current value Iecv to the capacity control valve 1a are input.
In step S4, it is determined whether or not a variation amount (a change amount within a predetermined time) of the compressor rotational speed Nc and a variation amount (a change amount within a predetermined time) of the controlled current value Iecv are within their respective threshold values and it is determined whether or not an operating condition of the air-conditioning device is stable. This determination is performed so as to suppress wrong diagnosis due to variations in a transient state.
When it is determined that the operating condition is stable, the process advances to step S5, in which an outlet pressure Pd of the compressor 1 and a refrigerant volume flow Gr are input. Here, the outlet pressure Pd of the compressor 1 is a refrigerant pressure on a high-pressure side of the vehicle air-conditioning device.
Subsequently, in step S6, a threshold value Th for determination of refrigerant leakage is calculated as a function f(Pd) of the outlet pressure Pd of the compressor 1.
More specifically, a maximum flow of the volume flow of the liquid-state refrigerant in such a state in which no refrigerant leaks is set as a basis. The reason is as follows.
When the refrigerant leaks, a total amount of the refrigerant flowing through the air-conditioning device becomes insufficient and a refrigerant density decreases. This makes it difficult for the refrigerant to condense in a condenser sufficiently and causes gaseous refrigerant to be mixed even in an area such as a condenser downstream in which the refrigerant is in a liquid state when no refrigerant leakage occurs. This accordingly causes a gas-liquid mixing state.
If a volume flow of the refrigerant in such a gas-liquid mixing state including the gaseous refrigerant having a low density is detected by a refrigerant flow detecting unit, the volume flow increases greatly as compared with a volume flow of the refrigerant in a liquid state which is detected in a normal condition, and exceeds even the maximum volume flow of the liquid-state refrigerant.
In view of this, the threshold value Th for determination of refrigerant leakage is set as the basis of the maximum flow of the volume flow of the liquid-state refrigerant in the normal condition as described above, thereby making it possible to determine the leakage of the refrigerant with high accuracy.
Here, the volume flow is obtained from a differential pressure between an outlet pressure Pd and an inlet pressure Ps of the compressor 1 and an opening degree of the expansion valve 3, and the volume flow reaches its maximum flow when the opening degree of the expansion valve 3 is largest in an operating condition causing the differential pressure (=Pd−Ps). Note that if the refrigerant leaks and gaseous refrigerant is mixed, the differential pressure increases and an apparent volume flow will increase. Since a change amount of the inlet pressure Ps is small as compared with a change amount of the outlet pressure Pd, a flow obtainable when the inlet pressure Ps is assumed constant and the opening degree of the expansion valve 3 is assumed largest is calculated as a possible maximum flow, for example, and a threshold value Th for determination of refrigerant leakage is set based on this value. For example, the value of the basis or a value obtained by increasing or decreasing this value by a predetermined amount is set as the threshold value Th for determination of refrigerant leakage.
Alternatively, a possible maximum flow corresponding to outlet pressure Pd in actual control is obtained by an experiment (a practical vehicle test, a bench test, etc.), simulation, or the like, and the threshold value Th for determination of refrigerant leakage may be set based on the maximum flow corresponding to outlet pressure Pd.
More specifically, by use of variables X and Y obtained from test data of the characteristic of the refrigerant volume flow Gr with respect to the outlet pressure Pd of the compressor 1 as illustrated in
Th=X·Pd
1/2
+Y
In step S7, the refrigerant volume flow Gr input in step S5 is compared with the threshold value Th for determination of refrigerant leakage set in step S6, and it is determined whether or not the refrigerant volume flow Gr is less than or equal to the threshold value Th for determination of refrigerant leakage.
If the refrigerant volume flow Gr is less than or equal to the threshold value Th for determination of refrigerant leakage, it is determined that no refrigerant leakage occurs, and the process advances to step S9.
On the other hand, if it is determined that the refrigerant volume flow Gr is greater than the threshold value Th for determination of refrigerant leakage, such a diagnosis result is given that refrigerant leakage occurs. When the refrigerant leakage occurs, the refrigerant is in the gas-liquid mixing state as mentioned earlier, and therefore, the volume flow increases and largely exceeds the possible maximum flow for the liquid-state refrigerant.
Accordingly, when the detected refrigerant volume flow Gr exceeds the threshold value Th for determination of refrigerant leakage which is set based on the maximum flow for the liquid-state refrigerant, it is determined that the refrigerant leaks, and a diagnosis result signal indicative of an occurrence of refrigerant leakage is output in step S8. Then, the process advances to step S9. Note that the diagnosis result signal may be output as warnings such as lighting of an alarm lamp.
In step S9, it is determined whether or not the air-conditioning switch is turned OFF. When the ON state continues, the process returns to step S3 and the diagnosis processing is continued. In the meantime, when it is determined that the air-conditioning switch is turned OFF, the diagnosis processing is finished.
Here, in a case in which, for example, the threshold value for determination of refrigerant leakage is set to a fixed value and is set to a low value, if the volume flow of the liquid-state refrigerant is large in a normal condition without any refrigerant leakage, a detected volume flow may exceed the threshold value and it may be wrongly determined that leakage occurs. On the other hand, in a case in which the threshold value is set to a high value, even if the refrigerant leakage occurs, a detected value of the volume flow is less than the threshold value and it may be difficult to give a diagnosis that the leakage occurs.
In contrast, in the present embodiment, even if the refrigerant flow varies according to the engine speed or the like, the threshold value Th for determination of refrigerant leakage is set to be changeable according to the operating condition of the air-conditioning device so as to reflect the variation. On this account, the refrigerant leakage can be diagnosed precisely without any restrictions from the operating condition.
In particular, in this embodiment, the threshold value Th for determination of refrigerant leakage Th is set by use of the outlet pressure Pd of the compressor, which is a parameter that could grasp a refrigerant flow most precisely only by itself. Thus, a precise refrigerant leakage diagnosis can be made by simple setting.
Furthermore, the expansion valve 3 is controlled so that its opening degree does not increase to a possible largest opening degree in a design normally while the air-conditioning device is being operated. Accordingly, the relationship between maximum flow and outlet pressure Pd in actual control may be obtained by an experiment or simulation, and the threshold value Th for determination of refrigerant leakage may be set based on the maximum flow corresponding to outlet pressure Pd.
Note that a map of the threshold values Th for determination of refrigerant leakage thus obtained may be set, so as to find a threshold value based on the outlet pressure Pd.
Furthermore, besides the outlet pressure Pd, the compressor rotational speed Nc, an environmental temperature (e.g., outside air temperature) Ta around the air-conditioning device which has an influence on a refrigerant state, or the like may be used together as parameters to set the threshold value Th for determination of refrigerant leakage. Even in this case, the threshold value Th for determination of refrigerant leakage can be set by setting a map or setting a multiple regression equation.
In a case in which a map is set by using the compressor rotational speed Nc, the outside air temperature Ta, or the like together, a main map for setting a basic threshold value based on the outlet pressure Pd and a correction map for correcting the basic threshold value by the compressor rotational speed Nc, the environmental temperature Ta, or the like are set as different maps, so that the threshold value Th for determination of refrigerant leakage can be set easily and precisely while reducing the total number of map data.
In this second embodiment, as illustrated in a broken line in
The process from step S1 to step S4 is the same as in the first embodiment.
When it is determined that the operating condition of the air-conditioning device is stable, the process advances to step S15, in which an outlet pressure Pd and an inlet pressure Ps of the compressor 1, and a refrigerant volume flow Gr are input. Here, the inlet pressure Ps of the compressor 1 is a pressure on a low-pressure side of the vehicle air-conditioning device.
Subsequently, in step S16, a threshold value Th for determination of refrigerant leakage is calculated as a function f(Pd, Ps) of the outlet pressure Pd and the inlet pressure of the compressor 1.
As described above, the volume flow reaches its maximum flow when the opening degree of the expansion valve 3 is largest in an operating condition causing a differential pressure (=Pd−Ps) between the outlet and inlet of the compressor 1. In view of this, the threshold value Th for determination of refrigerant leakage is basically set based on this maximum flow.
Alternatively, similarly to the first embodiment, the relationship between maximum flow and differential pressure (Pd−Ps) between the outlet pressure Pd and the inlet pressure Ps in actual control is obtained by an experiment (a practical vehicle test, a bench test, etc.), simulation, or the like, and the threshold value Th for determination of refrigerant leakage may be set based on the maximum flow corresponding to differential pressure (Pd−Ps) thus obtained.
More specifically, with the use of variables X and Y′ obtained from test data of the characteristic of Gr with respect to the differential pressure (Pd−Ps) as illustrated in
Th=X′·(Pd−Ps)1/2+Y′
A map of the threshold value Th for determination of refrigerant leakage may be set so as to find a threshold value based on the differential pressure (Pd−Ps), and besides the differential pressure (Pd−Ps), a compressor rotational speed Nc, an environmental temperature Ta, or the like may be further used as a parameter to set the threshold value Th for determination of refrigerant leakage. This is similar to in the first embodiment.
The process from step S7 to step S9 is the same as in the first embodiment.
That is, in step S7, a refrigerant volume flow Gr input in step S15 is compared with a threshold value Th for determination of refrigerant leakage Th set in step S16, and if it is determined that the refrigerant volume flow Gr is not less than the threshold value Th for determination of refrigerant leakage, a diagnosis result signal (alarm) indicative of an occurrence of refrigerant leakage is output in step S8, and this diagnosis flow is continued until it is determined that the air-conditioning switch is OFF in step S9.
According to the embodiment of the present invention, since the threshold value Th for determined of refrigerant leakage Th can be set based on the maximum flow obtained more highly precisely, based on the differential pressure (Pd−Ps) of the compressor 1, it is possible to diagnose whether or not any refrigerant leakage occurs, more precisely.
The process from step S1 to step S4 is the same as in the first embodiment.
When it is determined that the operating condition of the device is stable, the process advances to step S25, in which an outlet pressure Pd of the compressor 1, a controlled current value Iecv of the capacity control valve 1a, and a refrigerant volume flow Gr are input.
In step S26, an inlet pressure Ps of the compressor 1 is estimated as f(Iecv) based on a function value of the controlled current value Iecv. As described above, the capacity control valve 1a drives a valve element for opening and closing communication between a discharge side and an inlet side by the controlled current value Iecv, and controls a discharge volume in a variable manner by adjusting an intake pressure (=inlet pressure Ps). Accordingly, the controlled current value Iecv correlates with the inlet pressure Ps of the compressor 1, so that the inlet pressure Ps of the compressor 1 can be estimated as a function value f(Iecv) of the controlled current value Iecv.
In step 27, a threshold value Th for determination of refrigerant leakage is set in a similar manner to step S16 of the second embodiment with the use of the detected outlet pressure Pd of the compressor 1 and the estimated inlet pressure Ps.
The process from step S7 to step S9 is the same as in the first and second embodiments.
That is, in step S7, the refrigerant volume flow Gr input in step S25 is compared with the threshold value Th for determination of refrigerant leakage Th set in step S26, and if it is determined that the refrigerant volume flow Gr is not less than the threshold value Th for determination of refrigerant leakage, a diagnosis result signal (alarm) indicative of an occurrence of refrigerant leakage is output in step S8, and this diagnosis flow is continued until it is determined that the air-conditioning switch is OFF in step S9.
According to the third embodiment, similarly to the second embodiment, since the threshold value Th for determination of refrigerant leakage can be set based on the maximum flow obtained more highly precisely, based on the differential pressure (Pd−Ps) of the compressor 1, it is possible to diagnose whether or not any refrigerant leakage occurs, more precisely.
Furthermore, since the inlet pressure Ps of the compressor 1 is estimated as f(Iecv) based on a function value of the controlled current value Iecv, an inlet pressure sensor is unnecessary, which can attain low costs. Note that a current sensor is unnecessary because a value set according to calculation in the A/C ECU 22 can be used as the controlled current value Iecv.
Furthermore, as a modified embodiment of this third embodiment, an intake pressure may be controlled by the capacity control valve 1a, so that a stroke of a plunger for discharging the refrigerant is ultimately controlled in a variable manner. In a case in which an inclined angle of a swash plate for adjusting this stroke is detected, the inlet pressure Ps of the compressor 1 can be estimated based on a detected value of this inclined angle (see, in particular, Japanese Laid-Open Patent Publication No. 2003-301772).
In this fourth embodiment, as illustrated in a single dotted chain line in
The process from step S1 to step S4 is the same as in the first embodiment.
When it is determined that the operating condition of the air-conditioning device is stable in step S4, the process advances to step S35, in which an outlet pressure Pd of the compressor 1, an outlet temperature Teva of the evaporator 4, and a refrigerant volume flow Gr are input.
In step S36, the inlet pressure Ps of the compressor 1 is estimated as a function value f(Teva) of the outlet temperature Teva of the evaporator 4. A ratio between gas and liquid in the refrigerant changes inside the evaporator 4, but the temperature and the pressure are maintained to be substantially constant, and the outlet temperature Teva and the outlet pressure Peva of the evaporator 4 are correlated with each other.
The refrigerant discharged from the evaporator 4 is drawn into the compressor 1 while its state barely changes. On this account, the outlet pressure Peva of the evaporator 4 is substantially equal to the inlet pressure Ps of the compressor 1. In view of this, the inlet pressure Ps of the compressor 1 can be estimated as a function value f(Teva) of the outlet temperature Teva of the evaporator 4.
In step 37, a threshold value Th for determined of refrigerant leakage is set in a similar manner to step S16 of the second embodiment with the use of the detected outlet pressure Pd and the estimated inlet pressure Ps of the compressor 1.
The process from step S7 to step S9 is the same as in the first to third embodiments.
That is, in step S7, the refrigerant volume flow Gr input in step S35 is compared with the threshold value Th for determination of refrigerant leakage Th set in step S36, and if it is determined that the refrigerant volume flow Gr is not less than the threshold value Th for determination of refrigerant leakage, a diagnosis result signal (alarm) indicative of an occurrence of refrigerant leakage is output in step S8, and this diagnosis flow is continued until it is determined that the air-conditioning switch is OFF in step S9.
According to the fourth embodiment, similarly to the second and third embodiments, the threshold value Th for determination of refrigerant leakage Th can be set according to the maximum flow obtained more highly precisely, based on the differential pressure (Pd−Ps) of the compressor 1. This makes it possible to diagnose whether or not any refrigerant leakage occurs, more precisely.
Furthermore, in the air-conditioning device in which the outlet temperature Teva of the evaporator 4 is detected as a cooling air temperature, and control (refrigerant flow or the like) thereof is performed based on the cooling air temperature, the temperature sensor for the control can be diverted to thereby suppress an increase in cost.
Furthermore, although not illustrated here, as a fifth embodiment, in a case in which a target value of a refrigerant discharge volume of the compressor 1 is set and the refrigerant discharge volume is controlled to be closer to the target value, the threshold value Th for determination of refrigerant leakage may be set to, for example, a value slightly higher than the target value based on the target value of the refrigerant discharge volume.
In such a configuration, even if the refrigerant leaks in a small amount, it is possible to determine that refrigerant leakage occurs.
Furthermore, as illustrated in arrows in
Furthermore, in correspondence with the first to fourth embodiments illustrated in
In this configuration, since the operation of the compressor 1 is stopped when a refrigerant leakage is large, it is possible to suppress a further increase in the leakage of the refrigerant by the operation. Thus, this configuration is more preferable.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-133542 | Jun 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/062211 | 5/27/2011 | WO | 00 | 12/27/2012 |
