ancillary load reduction task overview - nrel · pdf file– ford lincoln navigator...
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Ancillary Load Reduction Task OverviewAncillary Load Reduction Task OverviewJohn Rugh, Task LeaderJohn Rugh, Task Leader
Desikan BharathanDesikan BharathanJasonJason LustbaderLustbaderMatthew KeyserMatthew Keyser
Center for Transportation Technologies & SystemsCenter for Transportation Technologies & SystemsNational Renewable Energy LaboratoryNational Renewable Energy Laboratory
August 2004August 2004
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Demand for Fuels Outstrips SupplyDemand for Fuels Outstrips SupplyDomestic Production with Transportation Use (1970Domestic Production with Transportation Use (1970--2020)2020)
0
2
4
6
8
10
12
14
1970 1980 1990 2000 2010 2020
GAP
Source: Transportation Energy Data Book: Edition 19, DOE/ORNL-6958, September 1999, and EIA Annual Energy Outlook 2000, DOE/EIA-0383(2000), December 1999
Mill
ions
of B
arre
ls p
er D
ay
Domestic Oil ProductionHeavy Trucks
Automobiles
Light Trucks
Pas
seng
er V
ehic
les
Vehicle Ancillary Load ReductionGoal
To work with industry to reduce energy use for vehicle climate control by 50% in the short-term and 75% in the long-term while maintaining passenger thermal comfort and safety.
Cool Car - ApproachTo develop integrated analysis tools and testing to analyze advanced climate control systems for a diverse supplier base from a systems perspective (thermal comfort, fuel economy, tailpipe emissions)
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Energy Used in Conventional Vehicle
Input100% (48.8)
Rolling5.0% (2.4)
Acc.2.8% (1.4)
Engine79.3% (38.6)
Aero.5.3% (2.6)
Driveline3.4% (1.7)
Braking2.5% (1.2)
21.3 city, 39 highway: 26.7 mpgge
w/AC10% (5.6)
Reduce Size of Existing AC SystemsWithout
AC
Energy Usage for Composite FTP & Highway Numbers in ( ) are MJ
Measured Insight and PriusFuel Economy Impacts from A/C
Measured Insight and PriusFuel Economy Impacts from A/C
53% increase in fuel use
43% increase in fuel use
Percent of Time AC UsedCooling + Demisting, 32.6%
1014
19
15
27
17
25
18
31
26
49
40
23
50
17
26
42
40
25
21
41
32
23
19
26
19
38
18
52
33
2024
37
28
50
3033
3225
23
26
69
41
57
2129
58 43
43
6
15
27
17
25
18
31
26
49
40
23
50
17
26
42
40
25
21
41
32
23
19
26
19
38
18
52
33
2024
37
28
16
50
3033
3225
23
26
69
41
57
28
21
2129
58 43
43
6
Percent of TimeAC for Cooling
+ Dehumidification
6.3 to 17.917.9 to 19.619.6 to 22.922.9 to 25.125.1 to 25.925.9 to 28.428.4 to 32.132.1 to 37.837.8 to 41.441.4 to 49.249.2 to 57.357.3 to 69.3
Modeled U.S. Mobile AC Fuel Use7.0 billion gallons used for air conditioning annually
Equivalent to 5.5% of the national fuel use, or ~9.5% of the imported crude oil!
1014
19
7
37
78
64
9
187
43
735
179
17
127
15
238
66
109
229
273
61
52
167
22
40
12
219
17
85
144
86186
21
118
176
9575
142242
26
68
68
251
753
76730
216 86
167
1
7
37
78
64
9
187
43
735
179
17
127
15
238
66
109
229
273
61
52
167
22
40
12
219
17
85
144
86186
21
118
86
176
9575
142242
26
68
68
251
753
19
61
76730
216 86
167
1
Million GallonsCooling &
Dehumidification
1 to 1717 to 2626 to 5252 to 6868 to 7878 to 8686 to 142142 to 176176 to 216216 to 242242 to 730730 to 753
European Union and Japan:Fuel Used for Cooling and Demisting
EU: 6.9 billion liters (1.8 billion gallons, 16 billion kg CO2) used for air conditioning annually, Equivalent to 3.2% of the total fuel use
Japan: 1.7 billion liters (0.5 billion gallons, 4 billion kg CO2) used for air conditioning annually, Equivalent to 3.5% of the total fuel use
United Kingdom
Turkey
Switzerland
Sweden
Spain
Romania
Portugal
Poland
Norway
Netherlands
Japan
Italy
Ireland
Hungary
Greece
Germany
France
Finland
Denmark
Czech Republic
Bulgaria
Belgium
Austria
Million GallonsCooling &Dehumidification
8 to 12
12 to 14
14 to 16
16 to 23
23 to 25
25 to 41
41 to 53
53 to 75
75 to 258
258 to 303
303 to 450
450 to 450
Why So Much Fuel for A/C?
150 Watts
Metabolic Heat Generation
A/C Cooling 6000 Watts!
Systems Approach
Traditional Approach - Equipment Emphasis
EFFICIENT EQUIPMENT
EFFICIENT DELIVERY
VERSUS
REDUCE LOAD
Decreases in load have a larger impact on fuel use due to equipment and delivery losses.
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Collaborative Projects with Ford
Lincoln Navigator Project
• Examine technologies to reduce solar heat gain– Improve thermal comfort– Improve fuel economy– Reduce emissions
Ford L/N Industry Partners• Shades, reflective and absorptive
– BOS Automotive• Window glazings, Solar Reflective
– PPG – Guardian Automotive
• Roof reflective films– 3M: Infrared reflective, visibly reflective
• Patterned glass– Solutia: VancevaTM Design Pattern
• Thermal insulation– 3M: ThinsulateTM– Lawrence Berkeley Lab gas filled panels
• Vehicle testing and data analysis– NREL
BOSBOS
Temperature Reduction Variable
% of maximum possible temperature reduction
All results referenced to (Tcabin- Tambient)baseline = 20°C
( )( )baselineambientaircabin
modifiedambientaircabin 1TTTT
−−
−=θ
Theta = 1, Tcabin,modified = Tambient
Theta = 0, Tcabin,modified = Tcabin,BL
Navigator ResultsSummary of Technologies
-10
0
10
20
30
40
50
60
70
80
90
100
Al Foil
Cab
inAl F
oil W
indow
sAl F
oil D
oors
and R
oof
Passiv
e Ven
t
Active
/Clos
ed V
ent 5
0 cfm
Reflec
tive S
hade
s
Infrar
ed R
eflec
tive W
indow
s
3M V
isibly
Refl
ectiv
e Roo
f Film
Panel
Insula
tion
Black A
bsorb
ing S
hade
s
Thet
a (%
)
Theta = 1, Tcabin,modified=TAmbient
Estimated Fuel Economy Impacts(L/N Cabin Results)
Technology Compressor Power Fuel Economy ImprovementPassive vent 34.0% 6.6 %, 1.1 mpgActive vent 24.0% 4.8 %, 0.76 mpg
Shades 14.3% 2.9 %, 0.45 mpgRoof film 9.4% 1.9 %, 0.3 mpg
Reflective Windows 11.4% 2.3 %, 0.36 mpgInsulation 6.6% 1.3 %, 0.22 mpg
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Collaborative Projects with DaimlerChrysler
DAIMLERCHRYSLER
DaimlerChrysler Grand Cherokee Test Project
• Examine technologies to reduce solar heat gain• Data for validating integrated modeling tools
DaimlerChrysler Industry Partners
• DCX - European Jeep Grand Cherokee– U.S. glazings installed prior to delivery
• PPG - Sungate® windshield, door sidelites• 3M - Thinsulate® acoustic/thermal insulation• NREL – Vehicle testing and data analysis
DAIMLERCHRYSLER
Integrated ModelingCAD
SolarRadiation Glazing
ThermalComfort
AirConditioning
Cabin Thermal/Fluid
Vehicle
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Integrated ModelingCAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Mesh the geometry of Mesh the geometry of your caryour car
Integrated ModelingCAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Find the solar radiation Find the solar radiation in your cityin your city
Find the heat coming Find the heat coming into your carIntegrated Modeling into your car
CAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Model temperatures Model temperatures and airflow in the cabinIntegrated Modeling and airflow in the cabin
CAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Integrated Modeling
QQcondcond
TTambamb
QQevapevap
QQsolarsolar
TTairairTTmassmass
WWcompcomp
CAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
FrontFront--EndEndAir FlowAir Flow
Accumulator /Accumulator /DryerDryer
ElectricElectric--DrivenDrivenCompressorCompressor
CondenserCondenser
Expansion DeviceExpansion Device(Orifice Tube)(Orifice Tube)
EvaporatorEvaporator
Evaporator Air FlowEvaporator Air Flow(Outside Air or (Outside Air or RecircRecirc.).)
MOTORMOTOR
AlternatorAlternatorGeneratorGenerator
Find the power consumption and Find the power consumption and cooling amount of the ACcooling amount of the AC
Integrated ModelingCAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Model your car over a drive Model your car over a drive cycle and find the fuel cycle and find the fuel
economyeconomy
How comfortable are How comfortable are you inside your car?Integrated Modeling you inside your car?
CAD
ThermalComfortVehicle
GlazingSolarRadiation
Cabin Thermal/Fluid
AirConditioning
FuelEconomy
TailpipeEmissions
OccupantThermal Comfort
Modeled Air Temperature ReductionBaseline• Gold exterior
• All Glazing - Sungate™• 25 scfm ventilation• White exterior
-7.9°C
ADVISOR Model Summary
Reducing the A/C system 32% can: – Improve fuel economy 6% or 1 mpg (SCO3)– Reduce emissions of NOx by 12.8% or 0.05 gr/mi
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Jeep Grand CherokeeParked Car Ventilation Test Program
Assess effect of:– Forced ventilation – Natural convection ventilation
DAIMLERCHRYSLER
Measured Cabin Air Temperature
30
32
34
36
38
40
42
44
46
Low flow / Panel Medium flow /Panel
Sunroof open6cm
Sidelites open2cm
Sunroof6cm/doublefloorvents
Sunroof6cm/double
floorvents/3 fans
Ventilation Technique
Cab
in A
ir Te
mpe
ratu
re (C
)
Ambient Temperature = 30C
Baseline Cabin Air Temperature = 45C
1.9C 13%
6.9C46%
2.0C13% 3.5C
23% 5.7C38%
7.5C50%
4.1 watts81 watts13 watts
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
DaimlerChrysler Test Cells Correlation: Outdoor vs. Indoor
Outdoor TestsEmissions Test CellSodium Scandium dosed Metal Halide
Environmental Test CellIR –Tungsten Filament
Quartz Tubes
DaimlerChrysler, DCTC, Auburn Hills, MI
NREL, Golden, CO How well do indoor tests simulate
outdoors?
Indoor Temperatures Compared to Outdoor
9/15/02 Environmental Conditions
30
35
40
45
50
55
60
65
70
75
80
Windshield IP Driver Seat Air, average Trim, average Vehicle Exterior
Tem
pera
ture
(C)
OutdoorMetal HalideIR
-3.4
+0.5
-4.8
-13.8
-1.4 -2.3
+1.5 +0.7 -0.1 -0.4
+20.1
+24.5
(Averaged between 1:30 and 2:00 p.m.)
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
JCI Distributed HVAC Project
Seat Body Coolers
IP Body Coolers
IP Recirc Inlet
Seat Recirc InletSeat Vent
• Assess human thermal comfort impact of JCI distributed HVAC system– Flow circulation & impingement– Steady state air temperature– Cooldown performance
Pathlines from Body Coolers and Seat Vents
Driver OverallEquivalent Homogeneous Temperature (EHT)
25
30
35
40
45
0 5 10 15 20 25
Time from Start of Cooldown (min)
Driv
er A
vera
ge E
HT
(°C
)
Baseline
Distributed HVAC
EHT – eqv. uniform temp. and 0 air velocity with same dry heat transfer as nonuniformtest conditions
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Thermal Comfort Assessment ToolsPredicting the comfort of vehicle occupants
Human Thermal Physiological
Model
Human Thermal Comfort Empirical
Model
ADvanced Automotive
Manikin
Manikin presentation PsychologicalPhysiological
ADvanced Automotive Manikin (ADAM)• On-board power, water, communications • Designed to respond to a transient, non-
uniform thermal environment like a human:• Sweating• Breathing
• Wears clothes• 175 cm tall, 61 kg• 126 elements (~120 cm2), 120 zones
Surface Segment DetailsOuter surface - low porosity metal
Distribution layer -high porosity metal
Water barrier layer
Fine grid distributed heater wire
Carbon fiber structural backing and insulation
Multiple temperature sensor array
Backside heat flux gauge
Local controller and fluid control valve
Segment with Exaggerated Sweat Rate
ADAM’s Carbon Fiber Skeletal System
Battery System
• 4 nickel-metal hydride modules
• Onboard charging • 2 hr capability
Modules in each thigh2 Modules in torso
ChargeController
Breathing System• 5 L/min periodic exhalation
and inhalation• 10 L/min continuous
exhalation• 100% R.H. at body
temperature
Valve
Humidifier chamber Breathing controller
Breathing System (cont.)
Tubes to nose
Nose breathing port
Neck auxiliary breathing port (inlet for continuous exhale mode)
IR Image of breathing
Heated plume of air
Fluid System Filter
• Added to mitigate contamination problem with segment capillary tubes
Fluid reservoirFilter
Fluid pump
ADAM’s Active/Inactive Segments
Ready for a Brain!
Human Thermal Physiological ModelA Numerical Person
• Predicts transient thermal response of the body
• Receives data from and provides data to ADAM
• ANSYS model (40,000 elements, transient, 3D)
• Fully parametric for size and position of the human
• Body mass (tissues, bones, organs)
Human Thermal Physiological ModelThermoregulatory System
• Circulatory system (network of circular tubes of variable cross sections for arteries & veins)
• Respiratory system (series of tubes between the mouth and lungs)
• Published control equations used for heat generation, sweat rate, shivering rate, vaso-dilation/constriction
Mesh
Section View of Upper Right Leg
Skin
Fat
Muscle
Bone
Circulation Network
FEA Model of the Flow Network of Upper Arm
• Thermal-flow elements:– Conduction within fluid – Mass transport of fluid – Convective heat transfer
coefficient to tissues varieswith fluid flow rate
• Cross-section of elements adjustable at every time step for vaso-dilation/constriction
Blood Vessel Temperatures
Hand Skin Temperatures
• Blood flow rate to arteries of 1380 cc/h @ 37ºC
• Muscle tissue 750 W/m3• Skin tissue 1005 W/m3
• Skin heat loss 100 W/m2
Body Skin Temperatures
Body Section Temperatures
Interface program
Substitute Table (model uses data from good segment in
place of a malfunctioning segment)
Heat flux multiplier(ability to adjust heat flux from ADAM)
The Human Thermal Comfort Empirical Model
How You Feel Thermally
• Determines local thermal sensation
• Determines local and global thermal comfort (thermal perception) from local sensations
• Accounts for non-uniform and transient thermal environment of vehicle cabin
Model Overview
PhysiologyTskin,local , Tskin,mean , Tcore
PhysiologyTskin,local , Tskin,mean , Tcore
Local Thermal Sensation: Sl
Local Thermal Sensation: Sl
Overall Thermal Sensation: So
Overall Thermal Sensation: So
Local Thermal Comfort: Cl
Local Thermal Comfort: Cl
Overall Thermal Comfort: Co
Overall Thermal Comfort: Co
Human Subject Testing
• Individual segments (plus breathing temperature) were heated and cooled
• 110 separate tests performed at U.C. Berkeley
• 64 tests performed in Delphi wind tunnel
Test Condition
0
10
20
30
40
0 50 100 150 200
Time (min)
Air
Tem
pera
ture
(°C
)
Test Condition
0
10
20
30
40
0 50 100 150 200
Time (min)
Air
Tem
pera
ture
(°C
)
Left Hand Cooling
0
5
10
15
20
25
30
35
40
15:36 15:43 15:50 15:57 16:04 16:12 16:19 16:26 16:33
Tem
pera
ture
(°C
)
-4
-3
-2
-1
0
1
2
3
4
Finger Temperature overall_sensation left_hand_sensation
Hand Cooling
Back Cooling
0
5
10
15
20
25
30
35
40
14:52 15:00 15:07 15:14 15:21 15:28 15:36
Skin
Tem
pera
ture
(°C
)
-4
-3
-2
-1
0
1
2
3
4
Back Temperature overall_sensation back_sensation
Back coolingTroom = 28.2°C
Body Core Heating With Local Cooling
37
37.1
37.2
37.3
37.4
37.5
37.6
13:
Tem
pera
ture
(°C
)
14:52 15:21 15:50 16:19 16:48
Pelvis CoolingLeft Hand CoolingHead Cooling
7:45
Troom=28ºC, Tsupply=12ºC
Physiological/Psychological Model Coupling
PhysiologyTskin Tcore
PhysiologyTskin Tcore
Local Thermal Sensation
Local Thermal Sensation
Overall Thermal
Sensation
Overall Thermal
Sensation
Local Thermal Comfort
Local Thermal Comfort
Overall Thermal Comfort
Overall Thermal Comfort
Converts temperatures to sensation and
comfort
Linking the Tools Together
Dynamic interaction with
environment
120 surface heat fluxes transmitted
Transmits 120 target skin temperatures and
sweat rates
Surface and core temperatures transmitted
Is the environment comfortable?
Model and Manikin Data Loop
FEA Output File of Ts
Model calculatesnew Ts setpoints and
writes to file ~2 minutesModel reads qlossevery ~2 minutes
Writes qloss to fileevery 15 seconds
Manikin Output File
of qloss
Manikin reads Ts setpoints,changes heater power, sweat
rate, and breathing
Manikin continuously adjusts heater power to meet Ts setpoints
Manikin Controlled by Model
Human & Manikin Comparison*>35.9°C
*<29.4°C
29.5
30.0
30.5
31.0
31.5
32.0
32.5
33.0
33.5
34.0
34.5
35.0
35.5
*>35.9°C
*<29.4°C
29.5
30.0
30.5
31.0
31.5
32.0
32.5
33.0
33.5
34.0
34.5
35.0
35.5
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
VCCL Objective
Evaluate occupant thermal comfort response to advanced cabin climate control systems in a controlled asymmetric, thermal environment and predict impact on:
• Fuel use• Thermal comfort
Cabin Thermal Test CellSolar Simulator
Air Conditioning System Passenger Compartment
Room Temp. Control(hidden)
Solar Simulator Uniformity Test
Air Conditioning• Actual Neon A/C
System• Electrically Driven
– 5.6 kW motor (7.5 hp)
Motor Starter& Power Switching
Condenser & FanMotor
Expansion Valve
DesiccantFilter
Compressor
Thermal Comfort Test ProcessHeat Soaked Vehicle
Cool-Down Test
TC & VehicleModeling
Improved ComfortEnergy &
Fuel Saving
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Objectives and Goals
• Our primary objective would be to utilize high-grade heat from engines in light-duty vehicles to produce cooling and/or electrical power generation.
• Our primary goal would be to reduce the fuel used by light-duty vehicles’ ancillary systems by 75% by 2010.
Availability of Waste Heat in a Light-Duty Vehicle
1000 1500 2000 2500 3000 3500 4000 45000
50
100
150
200
2030 40
50
60
70
80
90
100
125
15
175
200
300
400500
Engine S peed (rpm)
Eng
ine
Torq
ue (N
m)
Engine Waste P ower (kW), Max P ower 115 kW Based on 1991 Dodge Caravan 3.0-L (102 kW) S I Engine - trans ient da ta
• Average waste heat available would be 23 kW.
• Exhaust temperature varied from 200oC to 600oC.
• Generally, the waste heat available is twice as much as the mechanical output of the engine
Heat Generated Cooling Opportunities
Thermoacoustic EngineAbsorption Heat Pump Cycle
Zeolite/Desiccant Cooling Metal Hydride Heat Pump
Heat Generated Electric Generation
Evaporator
Preheater
Thermoelectrics, Thermionics, and Quantum Well Technologies Organic Rankine Cycle
Thermoacoutic Resonator
Waste Heat Utilization Laboratory
Long Term: Waste Heat Utilization
• Too long-term for industry
• Potentially eliminate all fuel used for air-conditioning
• Opportunities exist but require R&D
No More Fuel Used for AC!
Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects
– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation
– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing
– Johnson Controls Distributed Cooling• Future Opportunities
– A.D.A.M.– Climate Control Lab– Waste Heat Utilization
• Conclusions
Millions of Gallons Used
for AC per Year
0120241361481601722842962
6
34
67
33
8
21249
883
219
18
144
16254
39
123
203
304
79
64
191
20
43
11
238
18
104
166
86154
13
136
82
218
9686155257
26
73
98
275
962
20
63
87498
291102
205
0
Solutions to Reduce AC Fuel UseVehicle Design
• Reduce the load (e.g. cabin soak temperature)
• Improve distribution of cooling• Improve equipment efficiency• Effective tools (modeling and testing)
Future Opportunities• Implement integrated model with industry-
partnered vehicle testing to evaluate benefit of advanced climate control systems
• Evaluate advanced concepts with thermal manikin and modeling
• Demonstrate heat-generated cooling concepts
• Demonstrate heat-generated electricity concepts
Vehicle Level Opportunities• Reduced Fuel Consumption • Reduced Tailpipe Emissions• Increased Comfort• Avoided Costs - avoid second evaporator, tubes,
controls, ducts or larger system• Underhood Issues
– Space– Lack of air flow for cooling– Overheating components, particularly
battery and electronics– Condenser fan power
• Material life, color, and cost• Enable advance vehicle technologies
– HEV– FCV
Reduce compressor size and use
Acknowledgments• Roland Gravel, U.S. Department of
Energy, Office of FreedomCAR and Vehicle Technologies (OFCVT)
• Barbara Goodman, Director, NREL Center for Transportation Technologies and Systems
• Terry Penney, NREL OFCVT Technology Manager
• Charlie King, NREL Technician
Thank you
John Rugh303-275-4413
[email protected]://www.ott.doe.gov/coolcar
The U.S. Department of Energy’s
National Renewable Energy Laboratory