A Look At Automotive Air Conditioning Past, Present & Future

Early Automobiles
The early automobiles were not climate controlled :
- Passengers bundled up in the winter - Cooling was the breeze generated from vehicle top speed ..15mph.

Later, closed cabs were introduced and vehicle interior was unbearable !! Presentation by Jacob Bayyouk 7/18/02
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Air vents In vehicle floor

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Dirt & Dust Not much cooling

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Something had To be Done !!!

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The Early Days Of Cooling

Introduction Of Air Conditioning To Automotives

1930

1884
William Whiteley used blocks of ice: Placed in a tray under horse drawn carriage Blowing air inside the carriage by attaching fan to the axle

First car to be Air Conditioned. Customized Cadillac outfitted for John Hamman Jr.

1930s
Swamp Coolers
Evaporative cooling system : - Blowing air over water to reduce its temperature
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1939
Packard was the first mass produced car with air conditioning
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1939 Cadillac A/C prototype. A self contained unit in the trunk SAN DEN

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Introduction Of Air Conditioning To Automotives

1941 - Cadillac introduced 300 cars with air conditioning
Compressor Installed Under Hood Belt Removal Was Needed To Turn The System Off

Automotive Air Conditioning Compressors

40s - 60s Single (1) and dual (2) piston reciprocating compressors
Large / Bulky / Heavy

No Compressor Clutch

60s - 70s -Swash plate / Wobble plate fixed displacement compressors

Multiple pistons 5, 6, 7 , . 10 Smaller / Lighter/ Smoother operation

In the late 40s

A/C controls were introduced - However, Located in the rear of passenger compartment.

70s - 80s

- Rotary compressors - Internally Controlled Variable Wobble plate compressors

Smaller / Lighter/ Smoother operation -Scroll compressor introduction High speed/ Efficiency/Compact

1954 36,000 vehicles (approx.) had factory installed air conditioning. 1956 - All American car makers offerd air conditioning as an option. 1957 - All Cadillac Eldorado Broughams included A/C as a standard fea ture. 80s 2000s

In the 50s the usage of HCFC -22 was discontinued And was replaced by CFC -12
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-Electric variable speed compressors - Advanced swash plate compressors - Externally controlled variable displacement piston compressors
( With & W/O Clutch)

- New concepts are under development for Alt. Ref. ( i.e. CO2)

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Automotive Air Conditioning Challenged

1987
Montreal Protocol Complete Phase out of CFCs / Adoption of HFC -134a

Automotive A/C Compressors Of Today

Fixed Displacement, Swash Plate / Rotary Electric Scroll Compressor Scroll Compressor

The Industry Had To Move Rapidly And Adapt To New Rules / Regulations And Refrigerants
Recycle In the past things were simple No rules / regulations Single refrigerant And oil Now the industry had to deal with multiple issues & situations Things were no longer the same Moisture Concerns Recovery Multiple Lubricants Retrofits Multiple Ref. Contamination

Internally Controlled Variable Displacement Compressor

Externally Controlled Variable Displacement Compressor

The Industry Successfully Implemented The Change By 1994 All New Production In USA / Europe / Japan Was With HFC-134a
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Automotive A/C Scroll Compressor Cross Section View

Automotive Electric Scroll Comp. Cross Section View

Heat exchanger
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Automotive A/C Internally Controlled Variable Compressors

Internally Variable Displacement Piston Compressor Advantages

Internally Controlled Variable Displacement Compressor Construction / Cross Section View

Bellows Valve Rod Discharge pressure

Wide range capacity control (virtually eliminates clutch cycling)

Crankcase Crankcase pressure

Suction pressure Suction chamber

Crankcase Hinge

Shoe

Piston Control valve (MFCV)

Improved vehicle driveability And quieter operation Elimination of evaporator icing Improved fuel economy Greater reliability

Clutch Spring Swash plate Purdue Conference 2002 Orifice Suction chamber

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Internally Controlled Variable Displacement Compressor Displacement Control Concept

Control valve (MFCV) Blow-by gas

Automotive A/C Externally Controlled Variable Compressors

Externally Variable Displacement Piston Compressor Advantages

Suction chamber(Ps)
Compression

Suction gas
Improved comfort & energy efficiency through minimization of reh eat

Crankcase (Pc)

Orifice

Discharge chamber(Pd)

Discharge gas

Optimised displacement allowing improved engine management: -reduced fuel consumption - reduced emissions Allows for virtually zero displacement eliminating the clutch

Crankcase pressure is regulated by opening & closing of the control valve. The control valve has bellows which senses suction pressure. Therefore, the control valve regulates crankcase pressure to maintain desirable suction pressure, which is deter mined by the design of the valve itself. ( A very small amount of discharge gas flows into crankcase via the orifice. The purpose is to
stabilize displacement control at low heat loads.) Purdue Conference 2002

Higher speed operation

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Externally Controlled Variable Displacement Compressor Construction / Cross Section View

Solenoid Plunger Stator Shoe Torque limiter Valve Discharge gas Crankcase

Externally Controlled Variable Displacement Compressor Displacement Control Concept

Maximum Displacement

Maximum Displacement Control

Piston Variable orifice

Crankcase

Variable orifice
Blow-by gas

Suction chamber(Ps)
Compression

Suction gas

Pc=Ps
Discharge chamber

Control valve (EMPCV)

Control valve
(closed)

Discharge chamber(Pd)

Discharge gas

Bellows

Suction pressure

Hinge

Crankcase

Swash plate

Suction chamber

A higher control current is supplied to the control valve so that the passage from discharge chamber to crankcase is closed. The variable orifice has enough area to run blow-by gas into suction chamber. Therefore, the crankcase pressure & suction pressure tend to equalize and hence the cam angle increases to maximum. Purdue Conference 2002

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Externally Controlled Variable Displacement Compressor Construction / Cross Section View

Minimum Displacement Control
Piston Variable orifice

Externally Controlled Variable Displacement Compressor Displacement Control Concept

Minimum Displacement / Control State

Crankcase
Discharge chamber

Variable orifice
Blow-by gas

Suction chamber(Ps)
Compression

Suction gas

Pc>Ps

Control valve (Open)

Control valve
(Open)

Discharge chamber(Pd)

Discharge gas

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Crankcase

Swash plate

Suction chamber

The control valve has a bellows which senses suction pressure. T he change in displacement is achieved by the bellows adjusting the flow of discharge gas to the crankcase. A change in the current to the solenoid varies the force on the plunger which in turn modifies the set point controlled by the bellows.

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Automotive Air Conditioning Challenges Continues

The industry implemented HFC -134a successfully. While HFC-134a achieved : -Zero ozone depletion potential -GWP ~ 7 times less than CFC -12 Debate to replace HFC -134a started . And The push for Natural Refrigerants gained Momentum CO2 Became the leading Candidate. This direction was popular particular by European automotive industry. Environmental concerns remained HFC-134a GWP = 1300

Automotive Air Conditioning Challenges Continues

The Change From HFC-134a To CO2, What Is It ? Evolutionary Revolutionary

Evolutionary
1997 Kyoto The debates culminated in the Kyoto Conference HFC family was listed as one of the six substances That are most damaging to global warming. CFC-12 Change To HFC -134a Many similarities prevailed : -Pressures -Materials -Temperature - Components - Chemically

CO2 Safety Concerns The U.S. Automotive industry favored additional research to confirm suitable alternative Many differences exist :

Revolutionary
HFC -134a Change To CO2 - High Pressures -New Materials - Higher Temperature - New Components - Chemically -Safety

The Industry Is At Another Cross Roads

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Automotive Air Conditioning Challenges Continues

Alternative Refrigerant Future Direction !!!!!!!!!!
-The 1997 Kyoto Conference listed HFC family as one of the six substances that are most damaging to global warming. - Future vehicles will need auxiliary heat source (i.e. Heat pump, ..)

Automotive A/C Compressors Future Trends

Technology Level

el Fu

g vin Sa

Alternative Refrigerant
CO2

M
Hybrid compressor

Europe
especially VDA group

CO2 , DCX Germany indicated (@ 2002 Phoenix meeting)

Externally Controlled Compressor Internally Controlled compressor

Integrated Electric Compressor

on cti ote Pr tal en m on vir En

that they will introduce CO2 in their vehicles as early as 2005

USA, Japan

? Considering: (CO2 , R-152a, other..)

- CO2 - High pressure & cost - R152a - Potential flammability issue - Currently no specific plans

Electric Compressor

Advanced Fixed Displacement Line-up of Products

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EPA
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No specific preference. Endorses further R&D

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Automotive Air Conditioning Summary / Challenges

1884
William Whiteley Introduced Ice Blocks / Fan As A Cooling Device

Automotive Air Conditioning Summary / Challenges

87 - 90
Rapid Change In The industry To Design/Introduce HFC -134a System

1930

First Customized Vehicle With A/C Unit - Houston, Texas

91 -94

All New Production Was Converted to HFC -134a; USA/ Europe/ Japan

50s

HCFC-22 Usage Was Discontinued, CFC -12 Become Sole Refrigerant

1997

Kyoto Conference Listed HFC Family As One Of The Six Substances That Are Most Damaging To Global Warming

1974

Molins & Rawlins Discovery -- CFCs Depletion of Ozone Layer

2002

Industry Continuing Debate On Best Replacement Refrigerant To HFC-134a

70s

Efforts To Reduce System Charge / Reduce Leaks

1987

Montreal Protocol Complete Phase out of CFCs / Adoption of HFC -134a

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Future Refrigerant / Application Technology Projection

Future Vehicle Technology Projection

Gasoline engine Common rail Diesel engine Natural gas etc. Direct injection

,000

Gasoline Lean burn Advanced type

42V vehicle Hybrid vehicle Fuel cell vehicle Electric vehicle

Diesel

Direct injection Common rail

current

Year 2010

2010
80% (approx.) Is Expected To Be Internal Combustion Engine
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