Development of Carbon Dioxide (CO2) Applied Refrigeration System

<Compatibility of cooling performance and safety functions with the use of electrically controlled expansion valve>

Torahide Takahashi CalsonicKansei Corporation

2000

Contents of Presentation
1. Introduction 2. System Components & Specifications 3. Control Method 4. Results of Vehicle Tests 5. Summary 6. Future Activities
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1. Introduction
In the development of CO2 refrigeration systems, the challenge to be met is to assure the cycle safety and the required cooling performance at the same time, time due to the higher refrigerant gas pressure & temperature at the compressor outlet. (Compared with HFC134a systems) In order to meet this challenge, the CO2 refrigeration system we have developed uses an electrically controlled expansion valve.

With the introduction of this electrically controlled valve, our system has successfully achieved the required cooling performance and safety levels.

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2. System Components & Specifications 2-1 Components

Gas cooler Internal heat exchanger
C Electrically controlled expansion valve E D B Relief valve Pressure SW
Pressure (MPa) C B A

10

Pressure sensor 3.5 A Temperature sensor @

D@ 31C 0C

Enthalpy (J/kg) Mollier chart

Evaporator
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CO2 Refrigeration System Accumulator

Compressor
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2-2 Specifications of components

HFC134a system
variable displacement type, Compressor
swash plate

CO2 system
fixed displacement type,
swash plate

Displacement : 184 cc/rev Multi-flow type Gas cooler

Displacement : 30 cc/rev Multi-flow type

Core size (mm): 690W x 372H x 19D Core size (mm): 702W x 374H x 27D Frontal area: 0.257 m2 Frontal area: 0.262 m2

Laminate type Evaporator Internal heat exchanger Expansion Thermal expansion valve valve

Multi-flow type

Core size (mm): 235W x 265H x 64D Core size (mm): 265W x 213H x 88D Frontal area: 0.0628 m2 Frontal area: 0.0553 m2

Double tube serpentine type

Size: 19(dia) x 4 connections

Electrically controlled expansion valve

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2-3 Electrically controlled expansion valve

P (Pin]Pout) Compressor outlet pressure & temperature Up Down

Plunger Solenoid OUT

Outlet pressure: Pout Inlet pressure: Pin

Smaller Duty

Larger

IN Main valve Piston

Pilot valve

Solenoid applied voltage

a b

Time

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2-4 Vehicle installed condition

Evaporator (Passenger room)
Electrically controlled expansion valve

Internal heat exchanger

Compressor

Gas cooler

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3. Control 3-1 System control

Compressor outlet pressure (Mpa) Pmax P4 Mechanical pressure switch operation value P3 P2
Expansion valve control zone Compressor off value on temparature sensor Compressor off value on electric pressure sensor

Pressure limit Relief valve operation value

P0

nce a rm o f r pe one g re in rol z u l s o s Co cont pre ction w Lo ote e

pr zon

T0 T1

T2

Tmax

Expansion valve control zone Compressor outlet temperature (C)

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Thermal limit

P1

Protection control zone

3-2 Cooling performance control

Ambient sensor Passenger room temperature PTC set value Engine revolution Internal heat exchanger

Gas cooler

Control amplifier

Accumulator Pex Tex

Ps / Ts

Pd / Td

Proper duty value Electrically controlled expansion valve

Pe / Te Clutch

Compressor

Clutch

Evaporator

Intake air temperature sensor Evaporator back temperature sensor

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3-3 System protection control

(at gradual pressure & temperature rise)
Pmax

Compressor outlet pressure (Mpa)

P4 P3 P2 P1 P0 Gradual rise Protection control zone

g ance n i l Coo erform l zone p ntro co

Gradual rise

T0 T1

T2

Tmax

Compressor outlet temperature (C)

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3-3-1 Protection control at gradual pressure rise

Pressure (Mpa) Compressor OFF P2 Protection control zone Rising ratio determining P1 P0

Returning point

Cooling performance control zone 100

Expansion valve opening ratio (%)

Amplifier spec. value

0
Opening ratio will increase until the pressure becomes lower than the control returning value.

Time
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3-3-2 Protection control at gradual temperature rise

T2 Temperature (C) Compressor OFF Protection control zone Rising ratio determining Returning point Cooling performance control zone

T1 T0

Expansion valve opening ratio (%)

100
Amplifier spec. value

Opening ratio will increase until the temperature becomes lower than the control returning value.

Time
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3-4 System protection control

(at rapid pressure & temperature rise)
Pmax

Compressor outlet pressure (Mpa)

P4 P3 P2 P1 P0 Rapid rise Protection control zone

e g c n i n l a Coo rform l zone pe ntro co

Rapid rise

T0 T1

T2

Tmax

Compressor outlet temperature ( )

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3-4-1 Protection control at rapid pressure rise

Pressure (Mpa) P2 P1 P0 Compressor OFF Protection control zone Returning point Cooling performance control zone

Expansion valve opening ratio (%)

100
Amplifier spec. value

0 Time

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3-4-2 Protection control at rapid temperature rise

Temperature (C) T2 T1 T0 Compressor OFF Protection control zone Returning point Cooling performance control zone 100
Amplifier spec. value

Expansion valve opening ratio (%)

0 Time

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3-5 System protection control (at rapid engine revolution rise)

Engine revolution (min-1) 100
Expansion valve opening ratio (%)
Amplifier spec. value

Increase rate determination

0 Time

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3-6 Other protective functions

1) Evaporator anti-freezing function 2) Refrigerant leak protection 3) Compressor protection at its maximum speed operation.

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4. Vehicle Cool Down Test Results

50 Temperature (C) 40
Room Average
<Ambient conditions> Temperature: 40C Humidity : 50% Sun load: 1,050 W/m2

CO2 HFC134a 100 km/h Idling

40 km/h

30 20 10 0 0 10 20 30 50 40 Time (min) 60 70
18

Vent Outlet

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5. Summary
1) Same cooling performance level as the HFC134a system was achieved due to precise control of electrically controlled expansion valve. 2)Through the control on changing ratio of pressure and temperature, our CO2 system expanded operational zone. And our system reduced clutch on/off frequency and improved drivability.
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6. Future Activities
1) System weight reduction 2) System efficiency improvement 3) Further safety improvement

2000

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