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R744 MAC Systems from conventional driven vehicles to EVs

R744 MAC Systems from conventional driven vehicles to EVs. October 2009. Content. Natural Refrigerant R744 (CO 2 ) for MAC System Experience Phase 1: Functionality R744 AC & Heating System Phase 2: Performance AC & Heating Systems Phase 3: Controllability AC

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R744 MAC Systems from conventional driven vehicles to EVs

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  1. R744 MAC Systems from conventional driven vehicles to EVs October 2009

  2. Content • Natural Refrigerant R744 (CO2) for MAC • System Experience • Phase 1: Functionality R744 AC & Heating System • Phase 2: Performance AC & Heating Systems • Phase 3: Controllability AC • Phase 4: Driveability & Cost for Small Vehicles AC • Phase 5: COP System Optimisation AC • Phase 6: Durability Tests AC Systems • E-Vehicles, Hybrid electrical Vehicles and PHEV

  3. Why Natural Refrigerant R744 (CO2) • No ozone depletion; ODP = 0 • Lowest possible GWP of 1 • Classified under the American Standard Heating and Refrigeration (ASHRAE) as A1 • Non toxic and non flammable • R744 is one of the best known and understood substances in term of scientific research and applications. • Humans inhale and exhale it • Mankind puts it in soda and drinks it • It is a natural substance of the atmosphere • Highest efficiency, lowest indirect emissions and best LCCP vs. all others • Lowest total cost of ownership

  4. System Experience OE has build up more than 50 prototype vehicles with R744 – Systems • Future development trends towards • Electrical Vehicles with A/C and HP • HEV and PHEV with A/C and HP • Battery cooling • Thermal management

  5. OE System Experience AC & Heating Systems R744 Function AC Systems Only Performance System Control Small Vehicle COP System Durability Testing 2000 2004 2009 1997

  6. Phase 1: Functionality R744 AC & HS (1997-1999) • First development steps with R744: • Demonstrate that R744 operates as refrigerant under all climate conditions • Show the functionality of - Single AC-System - Coolantside Heat Pump System - Air Side Heat Pump System - Hot Gas Cycle System Therefore several cars were equipped with R744- Systems … … Audi … Daimler … BMW

  7. Phase 1: Functionality R744 AC & HS (1997-1999) System Description: Air Heat Pump System Heating Mode: IHX EXV Gascooler Air Air Evaporator Accu HVAC LP Valve P/T HP Valve Compressor

  8. Phase 2: Performance AC & HS (2000-2004) Optimisation of the Cooling- and Heating Performance in R744 Systems Vehicle model build up

  9. 50 kph REC 80 kph OSA IDLE REC 110 kph OSA 80 kph REC 50 kph OSA 10 K Comfort Temperature 22°C 18 min Phase 2: Performance AC & HS (2000-2004) AC Pull Down Results R744 vs. R134a (Full Size Truck)

  10. 14 min 21 min Comfort Temp. 22°C 28 min - R744 HG Cycle - Coolant & FFH - Coolant Phase 2: Performance AC & HS (2000-2004) • Heat Up Result Hot Gas System • R744 Hot Gas Cycle • Coolant & Fuel Fired Heater • Coolant Cabin Head Temperature Ambient temperature = -10°C

  11. Phase 3: Controllability AC (2002-2008) Pressure • Targets: • - Same or better controllability as R134a systems • Safe handling of the high system dynamic • Noise and torque optimised controlling Tunnel In Speed variation Tunnel Out 80 60 40 20 Blower variation Pressure [ bar ] Time [ min ]

  12. Phase 3: Controllability AC (2002-2008) Evaporator Temperature Setpoint Variation System conditions: Cycle: Forced Idle n_engine: 2000 rpm Blower: 7 T_Evap: Variable Compr.: Variable 12 °C 9 °C 9 °C 6 °C 6 °C 3 °C 3 °C • Stable outlet temperature • within the control range of • 3°C – 12 °C Time [ min ]

  13. Phase 4: Driveability & Cost for Small Cars (2004-2006) • Vehicle Build Up for Different OEMs • Small compressors, optimized heat • exchangers and control strategy have • been applied to show the AC functionality • in small cars with low torque engines

  14. ~ ~ Phase 4: Driveability & Cost Small Cars (2004-2006) Controlling Strategy Md [%] Pcomp [%] Engine torque MEng Pmax Max. Cooling power point PIdle Available engine torque Md [%] MCom MCom Compressor torque Compressor torque 35/120 bar 35/120 bar Adjustable max torque timing t [-] t [-] 1000 2000 3000 4000 5000 6000 1000 2000 3000 4000 5000 6000

  15. Phase 4: Driveability & Cost Small Cars (2004-2006) • Solution: Small Car Low Cost AC-Systems • Small size fixed or variable displacement compressor • Application adapted and optimized control strategy • Coaxial IHX as part of lineset • MCP Evaporator and Gascooler • Full Flexible Tubing System • PXV-System Result: Perfect drivability for small cars with R744 AC-Systems

  16. Phase 5: COP System Optimisation AC (2007-2009) The development phases 1 to 4 were focused on functionality and performance of R744 Systems Phase 5 was motivated to further improve COP and reduce fuel consumption of R744 AC systems

  17. Vehicle Test Results – Fuel Consumption NEDC Fuel Consumption Test R134a vs. R744 VW Touran TDI 1,9l; Tambient =20/28/35degC Additional Fuel Consumption l/100km T ambient Additional Fuel Consumption R134a Additional Fuel Cons. R744

  18. Phase 6: Durability Tests AC Systems (1999-2009) OE has built up several vehicles with different R744 systems for durability testing at Obrist and Costumers Obrist Engineering Vehicles (AC and Heating Systems) Ford Galaxy 1,9TDI AC & HG System and MCP Build up: 2003 Mileage: ~115.000 km R&D vehicle Audi A4 1.6l Single AC-System Build up: 1999 Mileage: ~113.000 km More then 10 years of city cycle operation !!

  19. Phase 6: Durability Tests AC Systems (1999-2009) OE has built up several vehicles with different R744 systems for durability testing at Obrist and Costumers Costumer Vehicles (AC Systems) VW Lupo 1,0 Single AC-System Build up: 2004 Accelerated Lifetime test 40.000 km Kia Sportage 1,9 TDI Single AC-System Build up: 2007 100.000 km Durability Test in Dubai

  20. EVs, HEVs and PHEVs • EVs, HEVs and PHEVs have additional needs for cooling and heating compared to conventional vehicles • Cabin heating and cooling • Battery cooling Efficiency in cooling and heating becomes key, since any energy required for heating and/or cooling needs has to be drawn from the battery • High battery cost • Range reduction issue

  21. EV Heating System Consequences Vehicle becomes useless

  22. Example: Air Side Heat Pump for EV High Efficient E-Compressor

  23. Li-Ion Battery Cooling System Development Coolant to Refrigerant to Air Battery Box CartridgeAC - System

  24. Summary • R744 Development for conventional driven vehicles completed • R744 Development for Evs, HEVs and PHEV under way • R744 is the future refrigerant since it is the only refrigerant fullfilling all the requirements for MACs and battery cooling systems • ODP and GWP • COP and Efficiency • Cost • HP capability

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