Optimization of Evaporator Core Temperature Control Using Active Thermocouple Array Sensor

Abstract

A method for generating a temperature map of the vehicle evaporator core is provided using an active thermocouple array sensor. The active thermocouple array sensor is attached to the HVAC enclosure and is positioned to read the temperature at multiple locations across the evaporator core. A controller generates a temperature map using data collected from the evaporator core by the active thermocouple array sensor. The temperature map facilitates optimization of the evaporator core temperature by the controller.

What is claimed is: 
     
         1 . A vehicle air conditioning apparatus comprising:
 a casing;   an evaporator core enclosed within the casing, the evaporator core having an air inlet face and an air outlet face, wherein the air inlet face is disposed opposite the air outlet face; and   an active thermocouple array sensor measures temperature at a plurality of   measurement points on the evaporator core to provide a plurality of temperature data points.   
     
     
         2 . The vehicle air conditioning apparatus of  claim 1  further comprising a sensor support disposed within the casing to position the thermocouple array sensor with a line-of-sight of the air outlet face to measure temperatures in an array on the air outlet face of the evaporator core. 
     
     
         3 . The vehicle air conditioning apparatus of  claim 1  wherein the plurality of measurement points is read as a temperature map. 
     
     
         4 . The vehicle air conditioning apparatus of  claim 3  wherein the temperature map allows the vehicle air conditioning apparatus to compensate for cold spot migration. 
     
     
         5 . A method of optimizing evaporator core temperature control comprising:
 assembling an active thermocouple array sensor within a vehicle HVAC casing;   positioning the active thermocouple array sensor to measure an airflow outlet face of an evaporator core;   gathering measurement data from the airflow outlet face of the evaporator core to develop a temperature distribution array data set;   analyzing the temperature distribution array data with a vehicle temperature control system; and
 programming the vehicle control system to maintain a minimum temperature 
   threshold on the airflow outlet face of the evaporator core based on the temperature distribution array data set.   
     
     
         6 . The method of optimizing evaporator core temperature of  claim 5  further comprising generating a temperature map from the temperature distribution array data set. 
     
     
         7 . The method of optimizing evaporator core temperature of  claim 6  further comprising analyzing the temperature map using a vehicle temperature control system. 
     
     
         8 . The method of  claim 5  wherein the minimum temperature threshold is in a range from 32° F. up to 38.5° F. 
     
     
         9 . An evaporator core temperature control system comprising:
 a vehicle HVAC system having a casing that directs a fluid through an evaporator core disposed within the casing, the evaporator core having an airflow inlet face and an airflow outlet face;   a thermocouple array sensor disposed within the casing in a line-of-sight relative to the evaporator core to measure a plurality of temperatures at a plurality of points on the evaporator core to generate a temperature map; and   a controller analyzes the temperature map of the outlet face to maintain the temperature across the evaporator core at a temperature above a minimum temperature threshold.   
     
     
         10 . The system of  claim 9 , wherein the controller analyzes the temperature map from the thermocouple array sensor to control the flow of a refrigerant in the evaporator core. 
     
     
         11 . The system of  claim 9  wherein the minimum temperature threshold is at least 32° F.