Society of Automotive Engineers Improved Mobile Air Conditioning Cooperative Research Program...

Society of Automotive Engineers

Improved Mobile Air Conditioning Cooperative

Research Program

Improved HFC-134a Refrigerant Systems

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

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

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

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

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

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

August 18, 2005 IMAC CRP 8

Team 1 Refrigerant Leakage

Reduction

•Goal:– Reduce HFC-134a Mobile Air

Conditioning System refrigerant direct emissions by 50%

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

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.

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

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

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

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

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

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

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

August 18, 2005 IMAC CRP 18

Team 3Vehicle Load

Reduction

•Goal:– Demonstrate vehicle level

technologies that reduce the cooling load by 30%

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

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

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

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

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

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

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

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

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

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

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