Improvement of Power Saving in R134a Air-Conditioning System

Masahide Ishikawa, Takayoshi Matsuno, TOYOTA MOTOR CORPORATION Kazuhito Miyagawa, DENSO CORPORATION

Presentation Outline
Impact of A/C on Fuel Consumption Approaches to A/C Power Saving
A/C Cycle & System Efficiency Improvement A/C Control Efficiency Improvement Coordination With Powertrain Vehicle Thermal Management Improvement

Influence of A/C on Fuel Consumption

Fuel Consumption (km/L)
15

9%

Actual Running Mode: Compact Car LA4: Stop Ratio 17%

Impact on Fuel Consumption

Components
Compressor, Condenser, etc

Yearly Temperature ( C) Humidity (%) 10 Sun Load (W/m2) Fresh / Recirculated Air Blower Speed 5
A/C Off A/C on (yearly)
o

25 50 0 Fresh Low 10

Influence of Vehicle Thermal Management Running Condition

Constant Speed, Acceleration/Deceleration Idling,

Evaporator Outlet Air o Temperature ( C)

Clutch (3)

Compressor (39)

Yearly (9%)
Cooling Fan (9) Blower (38) Idle up (11)

Electric load is also a major item.

Fuel Consumption Increase Ratio (%)

Impact on Fuel Consumption

Compressor (39)
9 38 3 11

Yearly (9%)
Assumption by Thermal Data at Idling and 40 km/h Running

Increase Evaporator Inlet o Air Temperature (5-10 oC) (4) o Re-Entry of Heated Air (10-15 oC) (4) Fuel Consumption Increase Ratio (%)

Thermal Management Improvement: Evaporator Air Inlet Temperature Reduction EPreventing Hot Air Recirculation
Constant Speed Accelerating Decelerating Idling

22

22

38

18

25

50 75 Fuel Consumption Increase Ratio (%)

100

LA4 Yearly (9%)

Large Effect When Idling and Decelerating (Accelerating In Summer) A/C Control Considering Running Condition Coordination Control with Powertrain
4

Approach to A/C Power Saving Impact on A/C Fuel Consumption

A/C Cycle , System & Components Personal Preference Running Condition Vehicle Heat

A/C Cycle & System Efficiency Improvement (including components) A/C Control Efficiency Improvement
5

Thermal Management Improvement Coordination with Powertrain

A/C Cycle

System Efficiency Improvement

Subcool Cycle & Improvement of Subcool condenser Improvement of Compressors Efficiency & Variable Displacement Compressor System

A/C Control improvement Coordination with Powertrain Vehicle Thermal Management Improvement

Condenser Efficiency Improvement

Q/F = Performance/(core width x core height) 180

High-performance Subcool
160 140 120 100 Serpentine 80 60 40 1980

Subcool type

Multi-Flow

Q/F

1985 7

1990

1995

2000

2005

2010

Operating Principle of Subcool Cycle

Subcooling
Pressure Subcool Reciever Condenser

Increase In Effective Refrigerant

GAS Exp.Valve Compressor Evaporator Liquid Enthalpy

Improved Cooling Performance

8

Effect of Subcool Condenser

10% Power Saving For Equivalent Performance
Subcool Condenser

5.7% 4500 Cooling Performance 4250 (kcal/h) 11.8%

Multi-Flow Condenser

2.0
Power Consumption (PS)

10%

1.5 600 9

780 700 800

Compressor Speed (rpm)

Condenser Performance Improvement

Mollier Diagram Subcool Effect
Subcool

1. Enhance Heat Transfer (Improved Tube & Fin Efficiency) Newest Conventional
1.7 mm 7.8 mm 1.0 mm 5.4 mm

Q Q +Q 16 mm

Subcool Effect Gives Q Extra Cooling

16 mm (approximate dimensions)

Effect
Compressor Load Ratio
100 90 80

2. Increased Core Effective Area Newest Conventional

Tank Height 11% Down Side Plate Height

Old

Current

10

Compressor Efficiency Improvement

0.7

Compressor Efficiency (%)

0.6

0.5

Latest Compressor Exceeds 70%.

0.4

HFC134a
1985 1990 1995 2000 2005

1980

Year
11

Continuously Variable Displacement Compressor

Max Displacement
Piston Piston StrokeFMax Pd Pc
Control@ Valve

Ps Pc = Ps
Piston Stroke

Partial Displacement
Piston StrokeFMax~Min Pd Pc
Control@ Valve

Shaft

Swash-Plate

Control@ Valve

Ps Pc
Piston Stroke

Ps

12

Characteristics of Variable Displacement Compressor

Analysis Method
5
V a ria b le D is p la c e m e n t C o m p . F ix e d D is p la c e m e n t C o m p (O N - O F F )

Divide into Compressor Efficiency and Cycle Performance

System COP

C o n d it o n e v a : 2 5 C 50% c o n : 2 5 C 2. 5 m / s S p e d = 1 600r p m V a = 3 00m 3/ h ( M 1)

4 3 2 1 16 14 12 10 8 6 4 2 0 .6 0 .4 0 .2 0 .0 0 .2 0 .4 0 .6 0 .8 1 .0

p practice k practice
System

k theory k practice
Comp. efficiency

p practice ~ k theory
Cycle

PdCTd

ad

Isentropic Process

PsC Ts k theory k practice

enthalpy@

Comp. Efficiency ad

Pressure@o

Cycle COP

bno

bno

Variable Displacement Comp System is improved. 13

Q/Q0

Effect of Variable Displacement Compressor System

Condit on e v a : 2 5 C5 0% c on :2 5 C2 .5 m / s Spe d= 1 600r pm Va= 3 00m 3 / h (M1 )

1.0 0.8 0.6

L/ o

0.4
Better
Torque

Torque

0] 100%/ON-OFF

In the performance controlled region, the variable displacement compressor system shows a better performance than the fixed compressor system

0.2 0.0 0.0 0.2 0.4

Variable Displacement Comp.

0.6

0.8

1.0

Q/ o
14

A/C Cycle

System efficiency improvement

A/C Control improvement

Power saving control Humidity control

Coordination with Powertrain Vehicle Thermal Management Improvement

15

Power saving Control using external variable compressor

Conventional Control (Internal Variable Compressor) Evap. Tin Te Temp. Tin
20deg.

Economy Control Logic

TEO ( C) Target of Air Temp. after Evaporator 15 10 5 0 0 5 10 15 20 25 30 35
o

H/C Tout

Demist

Power Saving

Comfort
Humidity External Variable Current: Internal Variable
o

Tout Te
3deg.

15deg.

Ambient Temperature TAM ( C) Power saving Control (External Variable Compressor) Evap. Tin Te Temp. Tin
20deg. Te 12deg.

Effect Power Consumption ratio -30%

1

H/C Tout

Tout

15deg.

Economy Conventional

16

Humidity Control (1)

Absolute Humidity(g/kg)
adopted by PRIUS
Relative Humidity

25 20 15 10 5 0 0

100% 80% 60% 40% 20%

Dehumidify

5 10 15 20 25 30 Temp.ij Cowl
Blower

Heater core Compressor

Evaporator Condenser

-Control the outlet air temp. & humidity by changing the evaporator temperature (TEO)
17

Humidity Control (2)

Configuration
Ambient sensor High-side Pressure sensor Exp. Evaporator Thermistor
Evap out Air temp Te High pressure Ph Ambient temp Ta Windshield humidity target: 90% Cabin humidity Target: 60%

Condenser Comp. Control Valve

Demist Evap out air temp. (

Humidity Comfort Zone

No Reheat With Humidity control

Demist Line
um tio m fica i 12 Min idi m hu de
0 0

w/o Humidity control 15 25 35

Ambient temperature (
Conditions: 25 C-50%

A/C ECU
Calculate: Duty ratio Comp power Cabin temperature and Humidity

Effect

Blower: M1

A/C Switch

w/o Humidity Control

-20%
With Humidity Control

Power Consumption Ratio

18

A/C Cycle

System efficiency improvement

A/C Control improvement Coordination with Powertrain Vehicle Thermal Management Improvement

19

Coordination with Powertrain Approach

Driving condition Drivers request Comp.Power Comp.

Engine

Output

(Driving)

Air-condition
Compressor management

Cooperative control E/G-A/C with external compressor

Displacement Control due to Cooling performance

Displacement control due to Compressor power

20

Control Pattern for Compressor Power Control

Acceleration Control
Reduce comp displacement during Acceleration Comp power Cooling consumption Performance Current (Ps control) New control Much Power saving with minimum performance reduction

Deceleration Control
Store the cool air during Deceleration
(Displacement: Maximum)

A/C fuel Comp power consumption consumption

Store cold air Discharge the cold air

Improve fuel Fuel cut consumption

Time

Time

n tio ra ele c Ac

Cruising Dec el e rat ion Stop(Idle)

Vehicle speed

Time

Compressor is run for required cooldown performance with minimum power consumption. 21

Idle speed is suitably controlled based on compressor power consumption.

A/C Cycle

System efficiency improvement

A/C Control improvement Coordination with Powertrain Vehicle Thermal Management Improvement
Reduction of Vehicle Heat Prevention of Heated Air Re-entry into Condenser

22

Vehicle Thermal Management Improvement

1. Reduction of Vehicle Heat Load
Heat Insulation (Roof) Heat Insulation (Pillar) Solar Radiation Absorption Glass (Rear)

Solar radiation Absorption Glass (Side)

Effect

Item Heat Insulation (Roof, Pillar) Solar Radiation Absorption Glass (Rear, Side) 23

Effect of Heat load reduction - 6% - 3%

Vehicle Thermal Management Improvement

2. Prevention of Heated Air Re-entry into Condenser
Shutter Stops Heated Air Re-Entry Shutter Engine Heated Air

Lower Cover Lower Cover

Shutter

Effect Condenser Inlet Air Temperature Reduced by 6 C

o

24

Example of Application to Vehicle

Toyota COROLLA
1

Power Consumption Ratio

Nearly 20% 0.9 0.8 0.7 0.6 0.5 1993 Model 2001

Subcool System Serpentine Condenser Subcool Condenser Compressor Improvement ad 0.62 ad 0.68

Power Consumption of Compressor After 30minutes at Idling

25

Summary
Many A/C Power Saving Technologies Have Been Developed;
A/C Cycle & System Efficiency Improvement A/C Control Efficiency Improvement Coordination With Powertrain Vehicle Thermal Management Improvement

Some Already Adopted in Mass-production Vehicles Technologies Will Be Further Expanded in the Future.

26