UltimateCooling System Application for R134a and R744 Refrigerant

Transcription

1 UltimateCooling System Application for R134a and R744 Refrigerant July 19th 2007 N.S. AP R&D Advanced Development Valeo Engine Cooling

2 CONTENTS Introduction: What s UltimateCooling How does UltimateCooling work? R134a applications Turbo diesel engine Turbo gasoline engine CO² application on Turbo diesel engine Advantages & Benefits Conclusion

3 WHY UltimateCooling? For Turbo diesel and Turbo gasoline engine, there are more and more Heat Exchangers in the Front End Insurance request (Danner) and Pedestrian crash regulation phase 2 (SAFE) Need more free space Overlapping of heat exchangers leads to interferences n Radiator performance polluted by A/C condenser n Available room reduced for pipes routing n Clearances between heat exchangers = wasted room Moreover, each heat exchanger is today sized for its own worst case condition (i.e. : A/C condenser at idle, radiator at full load). Conditions being not similar for all Heat Exchangers, lead to global over-sizing.

4 UltimateCooling : How does it work? Today design UltimateCooling A/C condenser : Refr. to air Refr. to low temp water Charge Air Cooler : air to air air to low temp water Oil cooler : oil to air oil to high/low temp water Fuel cooler : fuel to air fuel to low temp water EGR cooler : gaz to water gaz to hi/low temp water All engine fluids will be cooled by water need Multi-temperature (HT/LT) radiator

5 UltimateCooling : Application example Water charge air cooler (WCAC) is intergated in the engine air manifold on new VW 90kW TSI engine Extract from 28th International Wiener Motorensymposium 2007

6 UltimateCooling system applications on : Mercedes CDI : Turbo diesel engine hp Nissan Xtrail : Turbo gasoline engine 2.5 Refrigerant : R134a

7 Cooling module, WCAC and WCDS Baseline UltimateCooling Air Air > 118 mm mm Turbo diesel engine 2.2 L 140 HP Underhood volume 3 7 : + 4 dm3 Front-End volume : - 10 dm3 (- 40%) Overhang : - 58 mm (- 49%)

8 Coolant architecture of cooling module (low and medium speeds ) To Engine From Engine HT - LT Radiator Permanent HT Valve 1 Expansion tank HT/LT versus engine load Valve 2 R134a Fuel cooler WCAC LT Pass 1 LT Pass 2 Valve 3 WCDS EWP Permanent LT radiator R134a WCDS Add Receiver

9 Coolant architecture of cooling module (high speeds & hill climbing) To Engine HT - LT Radiator From Engine Permanent HT Valve 1 Expansion tank HT/LT versus engine load Valve 2 R134a Fuel cooler WCAC LT Pass 1 LT Pass 2 Valve 3 WCDS EWP Permanent LT radiator R134a WCDS Add Receiver

10 Cool down test results at Ta = 45 C on MercedesC 220 CDI Temperature ( C) Air Vent Outlet T ( C) Baseline Average Front Head T ( C) Baseline Air Vent Outlet T ( C) Ultimate Average Front Head T ( C) Ultimate km/h gear 3 Idle 90 km/h gear Time (mn)

11 Fuel consumption test results Fuel consumption (Liter/100km) ,1 Fuel consumption measurement (MVEG cycle) Cold start, A/C "on", blower max., Ta = 28 C 12-8 % - 6 % 9,2 8,7 6,8 6,8 Baseline Ultimate Baseline Ultimate Baseline Ultimate Urbain (L/100km) Ex-Ur. (L/100km) Average (L/100) Urbain (L/100km) Baseline Urbain (L/100km) Ultimate Ex-Ur. (L/100km) Baseline Ex-Ur. (L/100km) Ultimate Average (L/100) Baseline Average (L/100) Ultimate

12 Cooling module, WCAC and WCDS Baseline Engine UltimateCooling Engine Turbo gasoline engine WCDS CAC 47 mm HT Radiator A/C Condenser 27 mm HT Radiator LT Radiator CONDENSER RADIATOR WCDS WCAC RADIATOR Overhang reduction (mm) : - 42 % Cooling module volume (dm3) : - 38 % Cooling module weight (kg) : - 10 % Global volume (dm3) : - 42 % Extract from Fisita Paper n F2006P078

13 Test results : Engine Cooling, AC and Fuel consumption comparison UltimateCooling / Baseline nengine cooling performance : Generally similar or warmer but acceptable Air intake T is up to 4 to 20 C colder very good for acceleration and down sizing of engine Acceleration tests from 70 to 150 km/h : Air intake T remains constant, stable due to the inertia of coolant in the WCAC. nac performance : Similar to Baseline HP generally 2 Bars lower Fuel consumption with AC ON at Ta = 28 C (MVEG cycle) Up to 6%

14 UltimateCooling system applications on Audi A3 : Turbo diesel engine hp Refrigerant : R744

15 R744 A/C system: Front end air return issue R744 A/C system are very sensible to hot air circulation at idle due to faster enthalpy decreasing in respect with front air inlet temperature increase

16 Compact car issue: Hot air return at idle Front end modification to limit hot air return Gas cooler cartography at end of idle before modifications VDA conditions: 40 C, 40%, 1000W 71,4 51, ,7 Gas cooler cartography at end of idle after modifications VDA conditions: 40 C, 40%, 1000W 51,2 44,7 48,4 50,2 63,9 68,6 63,6 60,6 51,4 51,1 46,7 49,8 42,7 42,4 42,7 44,1 R744 outlet Gas cooler temperature: 62 C 46,7 42,2 42,7 44,2 R744 outlet Gas cooler temperature: 54 C

17 Compact car issue: Hot air return impact on performance Average carto- TRGO VDA Pull Down FXV- HP By Pass set point 122 bar C (I FE, air vent) - 8 C (I FE, Gas cooler outlet) TRGO IFE Average carto IFE Aver_Vent IFE TRGO Average carto Aver_Vent 8 C temperature reduction at gas cooler outlet leads to 5 C temperature reduction at vent outlet Front end management is mandatory to reduce R744 gas cooler temperature outlet Ultimate Cooling is an option to avoid that issue

18 A/C loop for R744 refrigerant UltimateCooling A/C system SLT loop LT loop HT loop WGC3 WGC2 WGC1 Expansion Valve Gas-cooler Conventional A/C system Evaporator Receiver Internal heat exchanger Externally Controlled Compressor

19 R744 P H diagram 3 stages of Water Gas Cooler IHX WGC3 WGC2 WGC Bars IHX 10 x=0,1 0,2 0,3 0,4 0,5 0,6 0, kj/kg 450 0,8 x=0,9

20 Coolant architecture of cooling module AIR LT radiator HT radiator SLT radiator To Engine CO² WGC1 From Engine Expansion tank HT radiator LT & SLT radiator WCAC LT Pass 1 LT Pass 2 S LT Radiator EWP WGC2 WGC3 CO²

21 AC performance at Ta = 45 C Similar to Baseline (R134a) Gear 3, 40 km/h Idle Gear 5, 90 km/h Temperature ( C) Ambiant Temperature Evapo Air Inlet Temperature Evapo Air Outlet Temperature Air Discharge (R744) Baseline Air Discharge (R134a) Time (s)

22 Advantages & Benefits Packaging reduction in Front End up to 40 % Overhang reduction up to 58 mm (- 50 %) Danner crash repair cost reduction No refrigerant leak after small crash (~ kg CO²/vehicle R134a) Better WCAC performance Down sizing of ICE Better engine performances and dynamic response during acceleration Fuel consumption reduction up to 6% (MVEG, Ta = 28 C, AC ON) Supply low temperature coolant to other fluids : fuel, EGR, oil, electronic and electric power-train for HEV, FCEV

23 CONCLUSION UltimateCooling system could be used and adapted for every refrigerants (R134a, R744, H, DP1, R152a, Ineos Fluor ) with : Better performance of engine Fuel consumption reduction Same AC performance as conventional AC system Crash test regulation conformity

24 THANK YOU!