Society of Automotive Engineers Improved Mobile Air Conditioning Cooperative Research Program Improved HFC-134a Refrigerant Systems
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