Improvement of Power Saving

in R134a Air-Conditioning System

Masahide Ishikawa, Takayoshi Matsuno,

TOYOTA MOTOR CORPORATION
Kazuhito Miyagawa, DENSO CORPORATION

1
 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

2
 Influence of A/C on Fuel Consumption
Impact on
Fuel Consumption (km/L) 15 9%
Actual Running Mode:
Compact Car LA4: Stop Ratio 17%
Fuel Consumption
Yearly
o
Temperature ( C) 25 Components
Humidity (%) 50 Compressor, Condenser, etc
10 Influence of Vehicle
Sun Load (W/m2) 0
Thermal Management
Fresh / Recirculated Air Fresh Running Condition
Blower Speed Low Constant Speed,
Acceleration/Deceleration
5 Evaporator Outlet Air Idling,
A/C Off A/C on o 10
(yearly)
Temperature ( C)

Compressor (39) Clutch (3)

Yearly
(9%)
Electric load is also
a major item.
Cooling Fan (9) Blower (38) Idle up (11)
Fuel Consumption Increase Ratio (%)

3
 Impact on Fuel Consumption
Compressor (39)
Yearly
9 38 3 11
(9%)
Increase Evaporator Inlet
Air Temperature (5-10 ooC) (4)oo Assumption by Thermal Data at
Re-Entry of Heated Air (10-15 C) (4) Idling and 40 km/h Running
Fuel Consumption Increase Ratio (%)
Thermal Management Improvement:
Evaporator Air Inlet Temperature Reduction Preventing Hot Air Recirculation
Constant Speed Accelerating Decelerating Idling
22 22 38 18 LA4
Yearly
(9%)
0 25 50 75 100
Fuel Consumption Increase Ratio (%)

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 Running Condition Vehicle Heat

Personal Preference

A/C Cycle &

System Efficiency Thermal
Improvement Management
(including Improvement
components)
A/C Control
Coordination
Efficiency with Powertrain
Improvement

5
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

6
 Condenser Efficiency Improvement
Q/F = Performance/(core width x core height)
180
High-performance Subcool

160 Subcool type

140 Multi-Flow

120
Q/F

100
Serpentine

80

60

40
1980 1985 1990 1995 2000 2005 2010

7
 Operating Principle of Subcool Cycle

Reciever

Pressure
Subcooling Subcool
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%
Cooling 4500
Performance Multi-Flow Condenser
(kcal/h) 4250
11.8%

2.0
10%
Power
Consumption
(PS)
780
1.5
600 700 800
Compressor Speed (rpm)

9
 Condenser Performance Improvement
Mollier Diagram Subcool Effect 1. Enhance Heat Transfer
Subcool (Improved Tube & Fin Efficiency)
Conventional Newest
1.7 mm 1.0 mm
7.8 mm 5.4 mm
Q Q
Q +Q 16 mm
Subcool Effect Gives Q Extra Cooling 16 mm (approximate dimensions)

Effect 2. Increased Core Effective Area

Conventional Newest
100
Compressor

Side Plate Height

Load Ratio

Tank Height
11% Down
90

80

Old Current

10
Compressor Efficiency Improvement

0.7

Compressor Efficiency (%)

0.6

Latest Compressor Exceeds

0.5 70%.

0.4
HFC134a

1980 1985 1990 1995 2000 2005

Year

11
Continuously Variable Displacement Compressor
Max Displacement
Piston Piston StrokeMax
Pd

Pc
ControlValve
Ps
Pc = Ps
Piston Stroke

Partial Displacement
Piston StrokeMax~Min
Pd

Pc
ControlValve
Shaft Swash-Plate Control Ps
Valve
Pc Ps
Piston Stroke

12
 Characteristics of Variable Displacement Compressor
C ondition
Analysis Method V a ria b le D is p la c e m e n t C o m p . eva:25 50%
F ix e d D is p la c e m e n t C o m p (O N - O F F ) con:25 2.5m /s
S peed=1600rpm
Divide into Compressor Efficiency V a=300m 3/h(M 1)
and Cycle Performance 5

System COP
practice theory practice 3

practice practice theory

1
System Comp. Cycle 16
efficiency 14

12
ad

Cycle COP
10
8
PdTd 6
4
Isentropic 2
Process
Pressure

0 .6

Comp. Efficiency
Ps
Ts 0 .4

theory ad
0 .2
practice enthalpy
0 .0 0 .2 0 .4 0 .6 0 .8 1 .0
Q/Q0
Variable Displacement Comp System is improved.
13
Effect of Variable Displacement Compressor System
Condition
eva:2550%
con:252.5m/s
1.0
Speed=1600rpm
Va=300m3/h(M1)
0.8 In the performance
controlled region, the
0100%/ON-OFF
variable displacement
Torque

0.6
compressor system
L/Lo

shows a better
0.4 performance than the
Better fixed compressor system
Variable Displacement
0.2 Comp.
Torque

0.0
0.0 0.2 0.4 0.6 0.8 1.0
Q/Qo

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) Economy Control Logic
Evap. H/C TEO ( C)
o
Demist Power Comfort
Tout Saving Humidity

Target of Air Temp.

External

after Evaporator
Tin 15
Variable
Te 10 Current:
5 Internal
Tin Tout
Temp.

20deg. 15deg. Variable

Te 0
3deg. 0 5 10 15 20 25 30 35
o
Ambient Temperature TAM ( C)

Power saving Control (External Variable Compressor) Effect

Power Consumption ratio

-30%
Evap. H/C 1
Tout
Tin
Te
Tin Tout
20deg. Te
Temp.

15deg.
12deg.
0
Economy Conventional

16
 Humidity Control (1)

Absolute Humidity(g/kg)
adopted by PRIUS
Relative Humidity
100%
25
80%
20
60%
15
10
40% Dehumidify
20%
5
0
0 5 10 15 20 25 30
Temp. Cowl

Blower
Heater core Evaporator

Compressor Condenser

-Control the outlet air temp. & humidity

by changing the evaporator temperature (TEO)
17
 Humidity Control (2)
Configuration Cabin humidity
Windshield humidity Target: 60%
Ambient sensor target: 90%
Humidity No
High-side Condenser Demist Comfort Zone Reheat
Pressure

Evap out air temp. ()

sensor Demist Line With
Comp. Humidity
Exp. n control
Control um atio
i m ic
Evaporator
Valve 12 Min idif
hum w/o
Thermistor de Humidity
control
Evap out 0
Air temp Te
0 5 15 25 35
Ambient temperature ()
High pressure Ph
A/C ECU
Ambient temp Ta Calculate: Effect Conditions: 25C-50% Blower: M1

Duty ratio
A/C Switch w/o Humidity Control
Comp power
-20%
Cabin With Humidity Control
temperature
and Humidity 0 1
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 (Driving)
Engine Output
Drivers
request
Comp.Power

Comp. Air-condition

Compressor management
Cooperative
control E/G-A/C with Displacement Control
external compressor due to Cooling performance

Displacement control
due to Compressor power

20
 Control Pattern for Compressor Power Control
Acceleration Control Deceleration Control
Store the cool air during
Reduce comp displacement
Deceleration
during Acceleration
(Displacement: Maximum)

consumption consumption
consumption Performance

Comp power
Current Store cold air

Comp power Cooling

(Ps control) Discharge
the cold air
Much Power
New control saving with
minimum
performance Improve fuel
Fuel cut consumption

A/C fuel
reduction

Time Time

Cruising Dec
Vehicle
speed

ion el e
l erat rat
ion
ce Stop(Idle)
Ac Time

Compressor is run for required Idle speed is suitably controlled

cooldown performance with based on compressor power
minimum power consumption. consumption.

21
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 Effect of Heat load reduction
Heat Insulation (Roof, Pillar) - 6%
Solar Radiation Absorption Glass (Rear, Side) - 3%

23
 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 Shutter

Lower Cover

Effect
o
Condenser Inlet Air Temperature Reduced by 6 C

24
 Example of Application to Vehicle
Toyota COROLLA
1

Power Consumption Ratio

Nearly 20% Subcool System
0.9 Serpentine Condenser

Subcool Condenser
0.8

Compressor Improvement
0.7 ad0.62

0.6 ad0.68

0.5

1993 2001
Model

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