thermal systems for vehicle thermal management, air
TRANSCRIPT
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Thermal Systems for Vehicle Thermal Management,
Air Conditioning, Heat Recovery and Future Fuels
Fakultät Maschinenwesen, Institut für Energietechnik, Bitzer–Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Ingolstadt, 26.09.2013
Prof. Dr.-Ing. U. Hesse Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Vehicle Thermal Management
Engine Cooling only
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 2
/http://pdphoto.org/PictureDetail.php?mat=pdef&pg=7906/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Vehicle Thermal Management
Electric Powertrain and Passenger Comfort
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 3
/ATZ-Online/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 4
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Road Map Vehicle Thermal Management
r future fuel
r electric powertrain
r waste heat recovery
r A/C with new refrigerants
r engine thermal management
r air conditioning (A/C)
r engine cooling and heating
r engine cooling only
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 5
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 6
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Temperature Levels
Combustion Engine
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 7
Heat Source Heat Sink
Te
mp
era
ture
Le
ve
l
A/C
Heater
A
mb
ien
t
Engine exhaust gas
Engine - coolant
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Temperature Levels
Electric Vehicle
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 8
Heat Source Heat Sink
Te
mp
era
ture
Le
ve
l
Range Extender
Thermal Storage (HT)
E - Motor
AC Inverter, DC-DC
Battery
A/C Thermal Storage (LT)
Battery
Heater
A
mb
ien
t
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Temperature Levels
Fuel Cell Electric Vehicle with LH2 Tank
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 9
Heat Source Heat Sink
Te
mp
era
ture
Le
ve
l
Fuel Cell
Thermal Storage (HT)
E - Motor
AC Inverter, DC-DC
Battery
A/C Thermal Storage (LT)
Battery
Heater
A
mb
ien
t
LH2 Tank
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temepature levels
• Engine thermal management
• MAC – mobil air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 10
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Combustion Engine Vehicle Thermal Management
• Automotive cooling systems
– designed for the highest necessary heat rejection
– this operating state is reached only during 3-5% of operation
– in most cases the thermal situation is subcritical
– the engine is overcooled
• A demand-responsive engine cooling system provides:
– 3 to 5 % reduced fuel consumption
– increased passenger comfort .. faster heat-up
– environmental compatibility .. reduced tail pipe emissions
• specific components
• specific control strategies
• demand-responsive cooling system
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 11
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Components of a Thermal Management System - Overview
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 12
/ SAE Technical Paper 1999-01-0238/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 13
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
Air conditioning only
• Refrigerant: R134a
• HVAC Evaporator
• Frontend Condenser
• Belt driven compressor - variable capacity - fixed capacity
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 14
/Source: IPETRONIK/
/Source: Behr/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 15
condenser
receiver
compressor
expansion valve
internal heat exchanger (optional)
evaporator
R134a system
Automotive Air Conditioning
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
• Passenger comfort
• Performance .. cool down
• Environment .. ozone depletion
• Environment .. global warming
• Enhanced efficiency .. fuel consumption => credits
• Extended functionality .. heat pumping, el. powertrain cooling (battery, inverter, DC/DC)
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 16
l
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
• Refrigerants: Transition CFC-12 to HFC-134a
– Omission of ozone depletion
– Significant reduction of global warming effect
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 17
F-gases: effect of globaly produced F-gases as Gt CO2 equivalent (grey: CFC and HCFC, red: HFC)
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
• 0,11 % of total global greenhouse emissions are due to the HFC refrigerants used in mobile air conditioning (MAC)
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 18
0,23 % refrigerants stat.
0,11 % refrigerants MAC
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
DIRECTIVE 2006/40/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 17 May 2006
• 1 January 2011: no type-approval for vehicle fitted with an A/C system designed to contain fluorinated greenhouse gases with a GWP > 150
• 1 January 2017: new vehicles fitted with an air-conditioning system designed to contain fluorinated greenhouse gases with a GWP > 150: (a) certificates of conformity no longer considered (b) registration refused and sale & entry into service prohibited
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 19
GWP (global warming potential): R134a: 1430, R1234yf: 4, CO2: 1 /IPCC/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
Refrigerants:
• HFO 1234yf
– Properties and behavior close to R134a
– GWP: 4 /IPCC/ resp. <1 /Reviews of Geophysics; Volume 51, June 2013/
– Serial vehicles already in the market
– Mildly flammable
– Ignition in presence of oil @ 600 .. 800 °C
– Decomposition products include hydrogen fluoride (HF, LC50 = 966 ppm) and carbonyl fluoride (COF2, LC50 = 360 ppm) /Graz, 2008/
– R1234yf: ignition of refrigerant in a test car after a simulated accident with a refrigerant leakage (some do some do not ignite)
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 20
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
Refrigerants:
• Natural refrigerants - hydro carbons, e.g. propane (R290) GWP = 3 - CO2 (R744) GWP = 1
• Propane:
– Similar pressure levels and components
– Efficient refrigerant
– Used already in not OEM approved „retrofit“
– Highly flammable => Secondary fluid needed => Reduced efficiency
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 21
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Automotive Air Conditioning
Refrigerants:
• CO2 (R744):
– Transcritical cycle
– Pressure level 120 to 160 bar (25 to 32 bar with R134a)
– All new components and control
– Also interesting for heat pump function
– Higher efficiency than R134a at lower ambient temperature
– Lower efficiency than R134a at high ambient temperature
– Development of application for MAC had been terminated in 2005
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 22
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
gac cooler
compressorexpansion
valve
internal heat exchanger
evaporator
CO2 system
accumulator
Cycle and Process with CO2 (R744)
transcritical process
pkrit = 7,38 MPa
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 23
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Specific enthalpy
lg (
Pre
ssure
)
35 bar
120 bar
Cooling
w a
Process with CO2 (R744)
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 24
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Specific enthalpy
lg (
Pre
ssure
)
20 bar
35 bar
120 bar
w/o a
Heating
Process with CO2 (R744)
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 25
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
/F. Wiescholek, Visteon, Small Cars with R744, VDA Wintermeeting, Saalfelden, 2007/
Cool Down Performance R744 / R134a
Ambient temp.: 43 °C, RH: 40 %, Sunload: 1000 W
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 26
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Efficiency R744 / R134a (SAE ARCRP 1)
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 27
/Pedrag Hrnjak, VDA-Wintermeeting 2007/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
CO2 Time Schedule
An approach:
• Restart of development
• Building base of serial suppliers
• Enhance efficiency and NVH (competitive to current R134a)
• Development
• Serial project development
• Process and industrialization
• Of tool samples
• Full validation
• SOP
• DIRECTIVE 2006/40/EC: phase out of R134a in all new cars by 1 January 2017
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 28
2013 2014 2015 2016 2017 2018
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 29
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
4-Way-Valve
CO2 Air / Air Heat Pump Cycle
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 30
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
CO2 Air / Air Heat Pump Cycle
4-Way-Valve
“flash fogging”
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 31
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
IF :
+ heating with „former“ evaporator
+ low ambient temperature
+ low wind shield temperature
+ high humidity
Flash Fogging
Limited Vision
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 32
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Advanced Heat Pump Cycle
engine
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 33
/SAE Phoenix 2004/
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Wind tunnel test: -20 °C
heating mode: after 5 min
engine
Heating mode
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 34
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Fuel Consumption
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 35
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Electric Powertrain
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 36
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Heat Pump for electric Vehicle
Assumption:
• Heating demand: 3 kW
• Distance: 180 km @ 60 km/h
• Energy Heating 9 kWh
• 45 % of a 20 kWh battery
+
battery
-
. QH
Pel
battery capacity
traction
heating
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 37
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Heat Pump for electric Vehicle
Assumption:
• Heating demand: 3 kW
• Distance: 180 km @ 60 km/h
• Energy Heating 9 kWh
• Heat pump @ a COP of 3
• 15 % of a 20 kWh battery
+
-
. QH
. Q0
Pel
battery capacity
traction
heat pump
saving
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 38
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuels
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 39
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Sept. 26th, 2013 40
Waste Heat Recovery
• Waste heat of a combustion engine
– Development of components and system e.g.: turbo, piston or scroll expander
– Conept: Rankin Cycle with natural working fluid
– Savings: up to 5% fuel consumption (long distance truck)
ICSAT Ingolstadt Hesse ThM
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 41
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Compressed Gas
Cryo-compressed
Liquid Solid storage
Source: Dynetek
Source: BMW
Source: BMW
•Physisorption
•Metal hydrides
•Complex hydrides
•Chemical hydrides
1 kg - 6 kg one or more pressure vessels
4 kg - 12 kg insulated cryogenic pressure vessel
7 kg - 12 kg insulated cryo-vessel
Hydrogen Storage
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 42
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Content
• Road map and definitions Thermal management
• Temperature levels
• Engine thermal management
• MAC – mobile air conditioning
– Working fluids
– Functionalities
• Waste heat recovery
• Future fuel
• Conclusion
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 43
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
Summary
• Management of different heat sources and heat sinks
• at different temperature levels
– From 22 K (LH2)
– Around ambient temperature
– Up to 800 K (exhaust gas)
• for powertrain component thermal management and climate control
– Conventional and electric powertrain
– Sustainable A/C and heat pump refrigerants
• Benefit
– Efficiency
– Function and durability
– Passenger comfort and safety
Sept. 26th, 2013 ICSAT Ingolstadt Hesse ThM 44
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Fakultät Maschinenwesen Institut für Energietechnik, Bitzer-Stiftungsprofessur für Kälte-, Kryo- und Kompressorentechnik
20.09.2013 45
Prof. Dr.-Ing. Ullrich Hesse
Technische Universität Dresden
Institut für Energietechnik
Bitzer Stiftungsprofessur für Kälte-, Kryo-
und Kompressorentechnik
01062 Dresden
Tel.: +49 351 463 32548
e-mail: [email protected]