society of automotive engineers improved mobile air conditioning cooperative research program...
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Society of Automotive Engineers
Improved Mobile Air Conditioning Cooperative
Research Program
Improved HFC-134a Refrigerant Systems
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August 18, 2005 IMAC CRP 2
Improved Mobile Air Conditioning (IMAC)
• Announced April 22, 2004• A comprehensive industry-government cooperative
research program to responsibly manage all aspects of lifetime vehicle air conditioner environmental performance– Develop and demonstrate improved vehicle air
conditioners using HFC-134a refrigerant– Add to customer value– Improve recovery and recycling of refrigerant during
service and vehicle end-of-life disposal• Participants include international automobile and air
conditioner system manufacturers, component and equipment suppliers, refrigerant manufacturers, MAC service providers and the Environmental Protection Agency
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August 18, 2005 IMAC CRP 3
Current 27 Corporate Sponsors
• Arkema (Autofina) • Audi • Behr • BMW• DaimlerChrysler • Delphi • Denso • DuPont • Ford • Fujikoki • General Motors • Goodyear• Honeywell
• Ineous Fluor • Japan Fluor Mfg Assoc • Manuli• Modine• Nissan • Parker Hannifin • Sanden • Schrader-Bridgeport• Solvay • TI Automotive • Toyota• Trelleborg• Viking Plastics • Visteon
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August 18, 2005 IMAC CRP 4
Project Goals
IMAC Core
Team 150% Leakage
Reduction
Team 330% Load Reduction
Team 230% Efficiency Improvement
Demonstration Vehicles2005/2006
Team 4Containment During
Service & Disposal
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August 18, 2005 IMAC CRP 5
IMAC Program Objectives
• Reduce “direct” HFC-134a refrigerant emissions that leak from MACs
• Reduce “indirect emissions”, which are emissions related to the burning of fuel needed to power the air conditioner
• Reduce any other emissions during the manufacture, installation, operation, servicing and disposal of the system
• Provide a directly comparative engineering evaluation – Existing and improved technologies – Vehicle and system design – Servicing of systems
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August 18, 2005 IMAC CRP 6
Project Organization
Tier One
Leakage Efficiency
•Overall Project Management•Financial Oversight•Funding strategy•Educate management
Members:•Tier 1 suppliers•Tier 2 suppliers•OEM’s•MACS and Members•EPA•Refrigerant Suppliers•Other
Members:•OEM’s•Tier 1 suppliers•NREL•EPA•University’s•Other
•Overall Technical Leadership•LCA & Cost Benefit Analysis•Sub-group Coordination
OEMCORE GROUP
OEM Advisors•GM•Ford•D-C
To advise in case of proprietary technologies
SAE
Industry
Members:•OEM’s•Tier 1 suppliers•NREL•University’s•Other
Members:•OEM’s•Tier 1 suppliers•EPA•MACS and members•Other
Vehicle Load Service
Tier Two
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August 18, 2005 IMAC CRP 7
IMAC Project Teams
Reduction in refrigerant losses at service
Load Reduction Improved comfort
Improved Efficiency
Reduction in
Leakage
Goals:
16346Others:
71813Tier1’s:
2345OEM’s:
2581624Number of Team Members:
Service refrigerant
loss Reduction
Vehicle Thermal
Load Reduction
AC System Efficiency
Improvement
Refrigerant
Leakage Reduction
Team Name:
Team4Team3Team2Team1
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August 18, 2005 IMAC CRP 8
Team 1 Refrigerant Leakage
Reduction
•Goal:– Reduce HFC-134a Mobile Air
Conditioning System refrigerant direct emissions by 50%
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August 18, 2005 IMAC CRP 9
Team 1 Progress to Date
• Identified 4 current production vehicles to baseline for refrigerant leakage rate– Dodge Caravan (dual system)– Ford F150– Toyota Camry– GM W Car
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August 18, 2005 IMAC CRP 10
Team 1 Progress to Date
• Evaluated mini-shed tests to establish refrigerant system direct emissions
• Evaluating assembly plant “noise factors” regarding assembly of system components free of contamination, damage, etc.
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August 18, 2005 IMAC CRP 11
Team 1 2006 Plan
• DevelopSAE Standard for component and system mini-shed test
Develop SAE Standard for reclaim procedure to determine actual vehicle charge level
Evaluate new low emissions technologies per standard
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August 18, 2005 IMAC CRP 12
Team 1 Description of Technologies
• Improved crimps• Improved fittings• Compressor shaft seal and body seals• Hose permeation• Material integrity-tubing• Reduced number of joints• TXV• Transducer/switches• Service valves/caps• Manufacturing/Assembly specifications• Leakage Test Procedure• Robust Manufacturing/Assembly Procedures
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August 18, 2005 IMAC CRP 13
Team 2System Efficiency
•Goal:– Improve system COP by 30% over
the enhanced R134a system that was demonstrated in the SAE Phase 1 Alternative Refrigerant Cooperative Research Program (ARCRP)
– Demonstrate equivalent performance
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August 18, 2005 IMAC CRP 14
Team 2 Deliverables
• Demonstrate COP improvement on a System Test Stand
• Demonstrate equal performance in a Vehicle Tunnel
• SAE J Standard for Measurement of System COP using the System Test Stand Approach
• SAE J Standard for Annualized Climate Calculation of System Power Loss
• Relative Cost / Benefit Analysis:– Cost will be relative on a 1-10 scale– Benefit will be COP improvement over the
enhanced R134a ARCRP system
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August 18, 2005 IMAC CRP 15
Team 2 2005 Plans
• System Stand:– Improved sub-cooling control (condenser)– Improved superheat control (evaporator)– Improved compressor efficiency– Internal (suction/liquid) heat exchangers
• Vehicle:– Sub-cooling and superheat algorithm
development– A/C performance demonstration
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August 18, 2005 IMAC CRP 16
Team 2 2006 Plans
• System Stand:– Next generation condensers (pending availability)– Next generation evaporators (pending availability)– Alternative compressor designs (pending
availability)– “Best of the Best” combination
• Vehicle:– Continue system development– A/C performance demonstration
• Develop J Standards• Develop Cost/Benefit Matrix
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August 18, 2005 IMAC CRP 17
Team 2Progress to Date
• Condenser sub-cooling control study shows potential for 20-30% improved COP at low loads (achieving control in a vehicle system is an open issue)
• Evaporator superheat control study shows potential for 20% improved COP at low loads
• Improved efficiency compressor study shows potential for 15% improved COP (climate weighted)
• Achieving the 30% improvement goal is promising but the individual effects may not be additive
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August 18, 2005 IMAC CRP 18
Team 3Vehicle Load
Reduction
•Goal:– Demonstrate vehicle level
technologies that reduce the cooling load by 30%
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August 18, 2005 IMAC CRP 19
Team 3 Progress to Date
• Tested the impact of various technologies on soak temperatures– Power ventilation device– Solar reflective glazing– Lightweight insulation– Sunscreen for windshield
• Plan to test additional technologies– Lightweight seats– Solar reflective paints
• Developing a computer model at the National Renewable Energy Lab (NREL) to estimate a technology’s impact on time to comfort and power consumption
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August 18, 2005 IMAC CRP 20
NREL vehicle Model
CAD
ThermalComfortVehicle
GlazingSolar
Radiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy &Emissions Cooling Capacity
&A/C Power
OccupantThermal Comfort
Front-EndFront-EndAir FlowAir FlowAccumulator /Accumulator /
DryerDryer
Electric-DrivenElectric-DrivenCompressorCompressor
CondenserCondenser
Expansion DeviceExpansion Device(Orifice Tube)(Orifice Tube)
EvaporatorEvaporator
Evaporator Air FlowEvaporator Air Flow(Outside Air or Recirc.)(Outside Air or Recirc.)
MOTORMOTOR
AlternatorAlternatorGeneratorGenerator
TTambamb
QevapQevap
QsolarQsolar
TTairair
TTmassmass
WcompWcomp
CondCond
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August 18, 2005 IMAC CRP 21
Team 3 Deliverables
Procedure for evaluation of technology Develop a ranking of approximate
cost/benefits for various technologies• Evaluation of technologies in laboratory
and fieldDemonstration vehicle for 2006 Phoenix
MeetingCommunication and education materials
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August 18, 2005 IMAC CRP 22
Team 4 Reduction in
Refrigerant Loss During Servicing
• Goals:– Evaluate and Recommend Improvements for
Service Tools, Equipment (New or Revised Standards) and Service Procedures
– Identify, Quantify and Propose Remedies for Refrigerant Losses at Service, Vehicle End of Life
– Quantify and Address Losses from One-Way Refrigerant Containers
– Produce Educational Materials and Conduct Outreach to Reduce Refrigerant Emissions
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August 18, 2005 IMAC CRP 23
Team Four – ServiceProgress & Plans
1. Leak detection tools, procedures
– Writing standards for next generation of tools
– Detection at 4 grams per joint/year(Current standard 14 grams)
– Probe distance 3/8” (now ¼”)– ‘Real world’ testing for standard
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August 18, 2005 IMAC CRP 24
Team Four – ServiceProgress & Plans
2. Service equipment, procedures
– Testing has shown that current recovery equipment/procedures leaves refrigerant in system
– Developing standard for next generation of equipment
– Different recovery procedures needed for different types of systems
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August 18, 2005 IMAC CRP 25
Team Four – ServiceProgress & Plans
3. Flexible coupled hose assemblies
– Conduct lab testing to evaluate field coupled assemblies for leakage
– Develop a cost-effective means of field evaluation of assemblies
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August 18, 2005 IMAC CRP 26
Team Four – ServiceProgress & Plans
4. Analytical tool to evaluateservice procedures
– SAE Service Technology Group Activity• Focus on leak detection; diagnosis
5. Refrigerant mass balance– Data collection to identify and
quantify the sources of all lifetime R-134a emissions
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August 18, 2005 IMAC CRP 27
Team Four – ServiceProgress & Plans
6. Vehicle end of life– Partnership with Automotive
Recyclers Association – Raise awareness in this sector– Develop strategies to improve
vehicle EOL refrigerant recovery
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August 18, 2005 IMAC CRP 28
Actual/Forecast Funding vs. Original Plans • Original 2004 announcement: “over $3 million
in cash and in-kind contributions”• Program on track to surpass initial funding plan
$ 000’s EPAFunds
IndustryFunds
In-Kind Industry
Total
CY 2004 60 60
CY 2005 370 560 900+ 1,830
CY 2006 370? 560? 900+ 1,830
Total 740 1,180 1,800 $3,720
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August 18, 2005 IMAC CRP 29
Status After One Year
• All 4 teams are operational and making progress
• Industry participation is high• The program is on track to
meet scope, funding and technical targets