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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
Prof. Hak Soo Kim ([email protected])
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VDA Alternative Refrigerant Winter Meeting 2008
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The next generation A/C Compressor – DOOWON Compressor
○ 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)
The next generation A/C Compressor – DOOWON Compressor
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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The next generation A/C Compressor – DOOWON Compressor
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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The next generation A/C Compressor – DOOWON Compressor
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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The next generation A/C Compressor – DOOWON Compressor
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
The next generation A/C Compressor – DOOWON Compressor
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
The next generation A/C Compressor – DOOWON Compressor
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)
The next generation A/C Compressor – DOOWON Compressor
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
The next generation A/C Compressor – DOOWON Compressor
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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The next generation A/C Compressor – DOOWON Compressor
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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The next generation A/C Compressor – DOOWON Compressor
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
The next generation A/C Compressor – DOOWON Compressor
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)
• Driving Condition
: Similar to R134a
• Idle Condition
• Driving 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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The next generation A/C Compressor – DOOWON Compressor
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,
DC28 COP is superior than R134a in the
3.0
acit
y (k
W),
DC28 COP is superior than R134a in the
all test conditions.
(Excluded 40℃ High load)
DC28 COP is superior than R134a in the
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)
The next generation A/C Compressor – DOOWON Compressor
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
ConclusionConclusion
100
120
)
2500
3000
3500
Highway HighwayIdle City Mode
Highway Condition
: Stable controllability
• Idle Condition
Highway Condition
: Stable controllability
• Idle Condition60
80
(bar)
, TE
MP (℃
2000
2500
ent
(mA)
Ps Ps set Idle Condition
: Stable controllability
• City Condition
Idle Condition
: Stable controllability
• 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
The next generation A/C Compressor – DOOWON Compressor
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
ConclusionConclusion
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
The next generation A/C Compressor – DOOWON Compressor
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
The next generation A/C Compressor – DOOWON Compressor
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)
The next generation A/C Compressor – DOOWON Compressor
Thank you for your interest.Thank you for your interest.
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