ultimatecooling™ system application for r134a and r744 … · 2019. 11. 5. · valeo engine...
TRANSCRIPT
UltimateCooling™ System Application for R134a and R744 Refrigerant
N.S. APR&D Advanced DevelopmentValeo Engine CoolingJuly 19th 2007
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
WHY UltimateCooling™ ?●For Turbo diesel and Turbo gasoline engine, there a re 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 interferenc es n Radiator performance polluted by A/C condensern Available room reduced for pipes routingn Clearances between heat exchangers = wasted room
●Moreover, each heat exchanger is today sized for it s 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.
UltimateCooling™: How does it work ?
A/C condenser : Refr. to air ���� Refr. to low temp waterCharge Air Cooler : air to air ���� air to low temp water Oil cooler : oil to air ���� oil to high/low temp waterFuel 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
Today design UltimateCooling™
UltimateCooling™: Application exampleWater charge air cooler (WCAC) is intergated in the engine air manifold on new VW 90kW TSI engine
Extract from 28th International Wiener Motorensymposium 2007
UltimateCooling™ system applications on :
●Mercedes CDI : Turbo diesel engine 2.2 140hp
●Nissan Xtrail : Turbo gasoline engine 2.5
Refrigerant : R134a
> 118 mm
Air
50-60 mm
Air
Cooling module, WCAC and WCDS
UltimateCooling™
Front-End volume 24Overhang 118
Underhood volume 3 7 : + 4 dm314 : - 10 dm3 (- 40%)60 : - 58 mm (- 49%)
Baseline
Turbo diesel engine2.2 L 140 HP
Coolant architecture of cooling module (low and medium speeds )
Fuel cooler
WCAC
WCDS
EWP
Permanent LT radiator
LT Pass 1
LT Pass 2
From EngineTo Engine
HT - LT Radiator
Permanent HT
HT/LT versus engine load
Valve 3
Valve 1
Expansion tank
WCDSAdd
Valve 2R134a
R134a
Receiver
Coolant architecture of cooling module (high speeds & hill climbing)
Fuel cooler
WCAC
WCDS
EWP
Permanent LT radiator
LT Pass 1
LT Pass 2
From EngineTo Engine
HT - LT Radiator
Permanent HT
HT/LT versus engine load
Valve 3
Valve 1
Expansion tank
WCDSAdd
Valve 2R134a
R134a
Receiver
Cool down test results at Ta = 45 °C on MercedesC 220 CDI
0
5
10
15
20
25
30
35
40
45
0 10 20 30 40 50 60 70 80 90
Time (mn)
Tem
pera
ture
(°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
40 km/h gear 3 90 km/h gear 5Idle
Fuel consumption test results
Fuel consumption measurement (MVEG cycle)Cold start, A/C "on", blower max., Ta = 28 °C
8,79,2
6,86,8
1213,1
0
2
4
6
8
10
12
14
Baseline Ultimate Baseline Ultimate Baseline Ultimate
Urbain (L/100km) Ex-Ur. (L/100km) Average (L/100)
Fue
l con
sum
ptio
n (L
iter/
100k
m)
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
- 8 % - 6 %
Cooling module, WCAC and WCDS
CONDENSER RADIATOR
WCACWCDS
RADIATOR
HT Radiator
A/C Condenser47 mm
Engine
HT Radiator27 mm LT Radiator
WCDS
Engine
Baseline UltimateCooling™
●Overhang reduction (mm) : - 42 %●Cooling module volume (dm3) : - 38 %●Cooling module weight (kg) : - 10 %●Global volume (dm3) : - 42 %
Turbo gasoline engine
CAC
Extract from FisitaPaper n°F2006P078
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%
UltimateCooling™ system applications on
Audi A3 : Turbo diesel engine 2.0 140hp
Refrigerant : R744
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 decreasi ng in respect with front air inlet temperature increase
Compact car issue: Hot air return at idle
71,4 51,5 52 62,7
63,9 68,6 63,6 60,6
42,7 42,4 42,7 44,1
R744 outlet Gas coolertemperature: 62°C
Gas cooler cartography at end of idle before modifications
VDA conditions: 40°C, 40%, 1000W
51,2 44,7 48,4 50,2
51,4 51,1 46,7 49,8
46,7 42,2 42,7 44,2
Gas cooler cartography at end of idle after modifications
VDA conditions: 40°C, 40%, 1000W
R744 outlet Gas coolertemperature: 54°C
Front end modification to
limit hot air return
Compact car issue: Hot air return impact on perform ance
Average carto- TRGOVDA Pull Down
FXV- HP By Pass set point 122 bar
0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80 90
TRGO IFE
Average carto IFE
Aver_Vent IFE
TRGO
Average carto
Aver_Vent
-5°C (I FE, air vent)
- 8°C (I FE, Gas cooler outlet)
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
A/C loop for R744 refrigerant
ExpansionValve
ExternallyControlledCompressor
Internalheat
exchanger
Gas-cooler
Evaporator
Receiver
WGC3 WGC2 WGC1
SLT loop LT loop HT loop
ConventionalA/C system
UltimateCooling™A/C system
R744 P–H diagram3 stages of Water Gas Cooler
10
30
50
70
90
110
130
150
0 50 100 150 200 250 300 350 400 450kJ/kg
0°
10°
20°
-10°
25°
15°
x=0,1 x=0,90,80,70,60,50,40,30,2
-10°Bars -20°-30° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° 110° 120° 160°140°
WGC1WGC2WGC3IHX
IHX
WCACWGC2
EWP
LT & SLT radiator
LT Pass 1
LT Pass 2
FromEngine
To Engine
HTradiator
Expansion tank
WGC3
WGC1
CO²
CO²
S LT Radiator
WCACWGC2
EWP
LT & SLT radiator
LT Pass 1
LT Pass 2
FromEngine
To Engine
HTradiator
Expansion tank
WGC3
WGC1
CO²
CO²
S LT Radiator
AIR
LT radiatorHT radiator
SLT radiator
Coolant architecture of cooling module
AC performance at Ta = 45 °CSimilar to Baseline (R134a)
0
5
10
15
20
25
30
35
40
45
50
55
60
65
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500
Time (s)
Tem
pera
ture
(°C
)
AmbiantTemperature
Evapo Air InletTemperature
Evapo Air OutletTemperature
Air Discharge(R744)
Baseline AirDischarge(R134a)
Gear 3, 40 km/h
Idle
Gear 5, 90 km/h
� 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 (~600-1000kg CO²/vehicle R134a)
� Better WCAC performance � Down sizing of ICE
� Better engine performances and dynamic response duringacceleration
� 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
Advantages & Benefits
� 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
CONCLUSION
THANK YOU !