the next generation a/c compressor doowon compressorr744.com/assets/link/08_vda_doowon.pdf · ·...

The next generation A/C Compressor – DOOWON Compressor

High efficiency R744 compressor development for vehicle

Prof. Geon Ho Lee P f H k S Ki

([email protected])

Prof. Hak Soo Kim ([email protected])

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© All rights with DOOWON Co.

VDA Alternative Refrigerant Winter Meeting 2008

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○ DOOWON Companies for Automotive A/C system ○ DOOWON Companies for Automotive A/C system

Doowon Climate Control Co.,LtdDoowon Climate Control Co.,Ltd DoowonDoowon Electronics Electronics Co.,LtdCo.,LtdDoowon Refrigeration Co.,LtdDoowon Refrigeration Co.,LtdDoowon Doowon Heavy Industry co. LtdHeavy Industry co. Ltd

A/C System C CA/C System Heat exchanger

ControllerElectric system

Compressor HVAC CasePipe

M d t (1 2 illi / ) D l tMass product (1.2 million/year) Development

Reciprocating t f B/C

Fixed Swash Plate t (150 170 )

Variable Swash Pl t t (90

R744 Swivel J i t t

Electric Scroll type

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type for B/C type (150cc, 170cc) Plate type (90cc, 130cc, 160cc )

Joint type( DC28)

type (DE27)


CONTENTS

I. Development Environmentp

II. DC28 R744 Compressor

III. DC28 Performance Test

IV. DC28 Vehicle Test

V. DC28 Master Project Plan

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I. Development Environment of DC28 R744 CompressorI. Development Environment of DC28 R744 Compressor

DC28(R744 Compressor)

Broad development experienceBroad development experience

Ability to develop the R134a

compressorInnovative Engineering Company

Matchp

Manufacturing Know-how

of Mass Production

as a R744 technical leader

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II-1. DC28 R744 Compressor SpecificationsII-1. DC28 R744 Compressor Specifications

MODEL DC28MODEL DC28

Type External Variable Displacement

Displacement Max 28cc/rev (~0-28cc/rev)Displacement Max. 28cc/rev (~0-28cc/rev)

Weight 4.5kg

Max rpm 11 000 (9 500 Continuous)Max. rpm 11,000 (9,500-Continuous)

Clutch Type Clutchless

Si Φ105 220Size Φ105x220mm

DC28 compressor can change the maximum displacement from 22cc to 33cc.

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II-2. DC28 R744 Compressor StructureII-2. DC28 R744 Compressor Structure

2.External Finfor cooling

1.Resin Pulleyfor weight

d ti

3.Controller with

reduction

Control valve and P-T Sensors

5.Swivel Joint Mechanismfor low friction loss and

4.Oil Separatorfor low oil circulation ratio

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hysteresis


II-3. DC28 R744 Compressor Advantages – External finsII-3. DC28 R744 Compressor Advantages – External fins

250250

191

160

200 191

160

200

Boundary ConditionsBoundary Conditionsw/o Fins

160149

150

Tem

p (℃

) 160149

150

Tem

p (℃

)

Boundary Conditions

• Heat output

on the inner walls

Boundary Conditions

• Heat output

on the inner walls

100

Housin

g T

100

Housin

g T: 600W

• Air speed

on the outer walls

: 600W

• Air speed

on the outer walls 4 Fins

5050

on the outer walls

: 50km/h

on the outer walls

: 50km/h

00

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w/o Fins 4 Fins 7 Finsw/o Fins 4 Fins 7 Fins7 Fins


II-3. DC28 R744 Compressor Advantages – SJ mechanismII-3. DC28 R744 Compressor Advantages – SJ mechanism

Swash Plate Swivel Joint

35

40

45

50

140

160

180

200

]

Mass flow downMass flow up

Torque downTorque up

Mass Flow

5

10

15

20

25

30

20

40

60

80

100

120

Torq

ue [N

m]

Mas

s Fl

ow [

kg/h

]

Torque

No correlation between valve signal and t

Correlation between valve signal and torque(2000 )

0

5

0

20

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Puls width [%]Control valve Pulse width [%]

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torque (2000 rpm)


II-3. DC28 R744 Compressor Advantages – Control strategiesII-3. DC28 R744 Compressor Advantages – Control strategies

DC28 i h i t t l t t i

Item w/ Integrated controller w/o controller Remarks

DC28 compressor is having two control strategies

Figure

Control logic Same R134a system control logic Need to change the control logicg y g g g

1. Simple Plug-In solution → No Change A/C ECU of R134a,

d l l t i

1. Low cost2. Compact size

Advantagesneed only electric power

2. Safety mode → control discharge pressure

3 Discharge pressure signal output

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3. Discharge pressure signal output


III-1. Volume & Overall Efficiency of DC28 R744 CompressorIII-1. Volume & Overall Efficiency of DC28 R744 Compressor

Volumetric Efficiency Overall Efficiency

(=Theoretical Power/Real Power)Remarks

100100

● Test Conditions

1. R134a80

90

100

DC2880

90

100

)

DC28 [R744] [R744]

- Discharge Pressure

: 15 bar

- Suction Pressure

: 2 bar60

70

CIE

NC

Y (%

)

R134a60

70

FIC

IEN

CY

(%

R134a

16%

30%[Swash plate]

Result

: 2 bar

- Suction SH

: 10 ℃

30

40

50

ERA

LL E

FFIC R134a

30

40

50

UM

ETIC

EFF

2. DC28(R744)

- Discharge Pressure

: 120 bar

- Suction Pressure10

20

30

OVE

10

20

30

VOLU

: 40 bar

- Suction Temp.

: 30 ℃

0500 1000 1500 2000 2500

COMP. RPM

0500 1000 1500 2000 2500

COMP. RPM

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III-2. VDA Durability Test III-2. VDA Durability Test

Test Conditions Test rig

-70 hours per one cycle

-Full durability test : 10 cycle 700 hours

-Speed range 700 to 9700rpm (11,000rpm 10 min)

Test Result

- Passed full durability test on Jan. 2007y

- There was 1.0~2.0% volumetric efficiency reduction between before and

after VDA durability test. ( at Ps=30bar, Pd=120bar, Rpm=1000~3000rpm)

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IV-1. Vehicle and R744 A/C SystemIV-1. Vehicle and R744 A/C System

Item Type

Type SUV

VehicleEngine 2700 cc

HP 175ps

T/M Auto

Compressor DC28 External Variable type [DWHI]

Gas Cooler Parallel Flow type [DCC]

Evaporator Parallel Flow type [DCC]R744 A/C system

p yp [ ]

IHX Co-axial type [DCC]

Accumulator 600 cc Al type [DCC]Accumulator 600 cc Al type [DCC]

PXV Mechanical type [Obrist]

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* Doowon Climate Control Co. install R744 A/C system in test vehicle


IV-2. Vehicle A/C Pull Down Test with DC28 R744 CompressorIV-2. Vehicle A/C Pull Down Test with DC28 R744 Compressor

R134a A/C system : 170cc Fixed Swash Plate type Compressor

Test condition : Ambient 35℃, 60%RH, 800W/㎡, Recycle Air, Blower Max. with SUV Vehicle

60.0

50kph 100kph Idle

• Initial Cooling• Initial Cooling

ConclusionConclusion

40.0

50.0

(℃)

Initial Cooling

: Better than R134a

• Driving Condition

Initial Cooling

: Better than R134a

• Driving Condition20 0

30.0

mpera

ture

(

Room Avg. (R134a)Room Avg. (R744)


: Similar to R134a

• Idle Condition


: Similar to R134a

• Idle Condition10.0

20.0

Tem

Vent Avg. (R134a)Vent Avg. (R744)

• Idle Condition

: Better than R134a

• Idle Condition

: Better than R134a0.0

0 15 30 45 60 75 90

Time (min)

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IV-3. Bench Test with DC28 R744 CompressorIV-3. Bench Test with DC28 R744 Compressor

Comparison of mechanical power and C O P on the same cooling capacity at 2000rpmComparison of mechanical power and C.O.P. on the same cooling capacity at 2000rpm.

R134a A/C System : 160cc Internal Variable Swash Plate Type Compressor

7 0

6.0

7.0

W),

CO

P Cooling Capacity - R744

Cooling Capacity - R134a

Power - R744

Cooling capacity

ConclusionConclusion4.0

5.0

Pow

er (

kW Power - R134a

COP - R744

COP - R134a

• On the same cooling capacity,

DC28 COP is superior than R134a in the

• On the same cooling capacity,


3.0

acit

y (k

W),


all test conditions.

(Excluded 40℃ High load)


all test conditions.

(Excluded 40℃ High load)1.0

2.0

oolin

g C

apa

C.O.P. (Excluded 40℃ High load)(Excluded 40℃ High load)

0.0Low High Low High Low High

20℃/50%RH 30℃/40%RH 40℃/40%RH

Co

Evap. →Air Flow

C.O.P.

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20℃/50%RH 30℃/40%RH 40℃/40%RH

Test Conditions (2000rpm)


IV-4. Vehicle A/C Controllability Test with DC28 R744 CompressorIV-4. Vehicle A/C Controllability Test with DC28 R744 Compressor

120 3500

Operating Conditions : SUV Car, In Dubai , T_amb 35℃ , A/C Controller 22℃ auto setting

• Highway Condition• Highway Condition


100

120

)

2500

3000

3500

Highway HighwayIdle City Mode

Highway Condition

: Stable controllability

• Idle Condition

Highway Condition


• Idle Condition60

80

(bar)

, TE

MP (℃

2000

2500

ent

(mA)

Ps Ps set Idle Condition


• City Condition

Idle Condition


• City Condition

40

PRES

SURE

(

1000

1500

Curr

Ps_set

City Condition

: In spite of changing

speed, suction pressure

City Condition

: In spite of changing

speed, suction pressure0

20

0 1200 2400 3600 4800 6000 7200

0

500

had stabilized within

±1.5 bar

had stabilized within

±1.5 bar

0 1200 2400 3600 4800 6000 7200

TIME (sec)

Discharge Pressure Suction Pressure Suction Pressure_set A/C Signal

Real value Target value

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Real value Target value


IV-5. Off mode test in vehicle with DC28 R744 CompressorIV-5. Off mode test in vehicle with DC28 R744 Compressor

Test conditions : T_amb 12 ℃, A/C Off, Free driving speed

180

200

4,000

5,000

140

160

2,000

3,000

Eng. rpm ▶

80

100

120

SPEE

D (

kph)

1 000

0

1,000

. RPM

2.0 – 3.5 bar

40

60

80

ESSU

RE

(bar

),

-3,000

-2,000

-1,000

ENG

◀ High pressure◀ Low pressure

2.0 3.5 bar

0

20

0 60 120 180 240

PRE

-5,000

-4,000 ◀ Vehicle speed◀ Ambient temp.

In spite of changing vehicle speed, the pressure difference between suction and discharge is 2.0~3.5bar Thi l t PXV i lIn spite of changing vehicle speed, the pressure difference between suction and discharge is 2.0~3.5bar Thi l t PXV i l


0 60 120 180 240

TIME (sec)

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This pressure value can not open PXV expansion valve. This pressure value can not open PXV expansion valve. ConclusionConclusion


IV-6. Vehicle Durability Test with DC28 R744 Compressor IV-6. Vehicle Durability Test with DC28 R744 Compressor

T t 100 000 k ith SUV (2 )Target : 100,000 km with SUV (2 cars)

22. Mar. 2007 ~ 18. Jul. 2007 (105 days, 1260 hrs) / UAE Dubai

hi lhi lNo. 1 VehicleNo. 1 Vehicle

No 2 VehicleNo 2 Vehicle

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No. 2 VehicleNo. 2 Vehicle


IV-6. Vehicle Durability Test with DC28 R744 CompressorIV-6. Vehicle Durability Test with DC28 R744 Compressor

60.0 120,000

38 53

40 0

50.0

)

80 000

100,00038 – 53

30.0

40.0

atu

re (℃

)

60,000

80,000

ge (km

)

Mileage : 100,000 km(2007.07.18)

20.0Tem

pera

40,000

,

Mile

ag

Amb. Temp. (℃)

Mileage (km)

10.0 20,000

0.007/3/22 07/4/1 07/4/11 07/4/21 07/5/1 07/5/11 07/5/21 07/5/31 07/6/10 07/6/20 07/6/30 07/7/10 07/7/20

Day (yy/mm/dd)

0

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Day (yy/mm/dd)


Thank you for your interest.Thank you for your interest.

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