Society of Automotive Engineers
Improved Mobile Air
Conditioning Cooperative
Research Program
Improved HFC-134a
Refrigerant Systems
Improved Mobile Air
Conditioning (IMAC)
• Announced April 22, 2004
• A comprehensive industry-government cooperative
research program to responsibly manage all aspects of
lifetime vehicle air conditioner environmental performance
– Develop and demonstrate improved vehicle air
conditioners using HFC-134a refrigerant
– Add to customer value
– Improve recovery and recycling of refrigerant during
service and vehicle end-of-life disposal
• Participants include international automobile and air
conditioner system manufacturers, component and
equipment suppliers, refrigerant manufacturers, MAC
service providers and the Environmental Protection Agency
August 18, 2005 IMAC CRP 2
Current 27 Corporate Sponsors
• Ineous Fluor
• Arkema (Autofina)
• Japan Fluor Mfg Assoc
• Audi
• Manuli
• Behr
• Modine
• BMW
• Nissan
• DaimlerChrysler
• Parker Hannifin
• Delphi
• Sanden
• Denso
• Schrader-Bridgeport
• DuPont
• Solvay
• Ford
• TI Automotive
• Fujikoki
• Toyota
• General Motors
• Trelleborg
• Goodyear
• Viking Plastics
• Honeywell
• Visteon
August 18, 2005 IMAC CRP 3
Project Goals
Team 4
Containment During
Team 1
Service & Disposal
50% Leakage
IMAC Core Reduction
Team 2
30% Efficiency
Improvement
Demonstration Vehicles
2005/2006
Team 3
30% Load
Reduction
August 18, 2005 IMAC CRP 4
IMAC Program Objectives
• Reduce “direct” HFC-134a refrigerant
emissions that leak from MACs
• Reduce “indirect emissions”, which are
emissions related to the burning of fuel needed
to power the air conditioner
• Reduce any other emissions during the
manufacture, installation, operation, servicing
and disposal of the system
• Provide a directly comparative engineering
evaluation
– Existing and improved technologies
– Vehicle and system design
– Servicing of systems
August 18, 2005 IMAC CRP 5
Project Organization
•Overall Project Management
CORE Tier One Tier Two OEM Industry •Financial Oversight
•Funding strategy
GROUP •Educate management
SAE
Leakage Efficiency Vehicle Load Service
Members: Members: Members: Members: •Overall Technical
•Tier 1 suppliers •OEM’s •OEM’s •OEM’s Leadership
•Tier 2 suppliers •Tier 1 suppliers •Tier 1 suppliers •Tier 1 suppliers
•LCA & Cost Benefit
•OEM’s •NREL •NREL •EPA
•MACS and •EPA •University’s •MACS and Analysis
Members •University’s •Other members •Sub-group
•EPA •Other •Other Coordination
•Refrigerant Suppliers
•Other
OEM Advisors
•GM
•Ford To advise in case of proprietary
•D-C technologies
August 18, 2005 IMAC CRP 6
IMAC Project Teams
Team1 Team2 Team3 Team4
Team Name: Refrigerant AC System Vehicle Service
Leakage Efficiency Thermal refrigerant
Reduction Improvement Load loss
Reduction Reduction
Number of Team 24 16 8 25
Members:
OEM’s: 5 4 3 2
Tier1’s: 13 8 1 7
Others: 6 4 3 16
Goals: Reduction Improved Load Reduction in
in Efficiency Reduction refrigerant
Leakage Improved losses at
comfort service
August 18, 2005 IMAC CRP 7
Team 1
Refrigerant Leakage
Reduction
• Goal:
– Reduce HFC-134a Mobile Air
Conditioning System refrigerant
direct emissions by 50%
August 18, 2005 IMAC CRP 8
Team 1
Progress to Date
• Identified 4 current production
vehicles to baseline for refrigerant
leakage rate
– Dodge Caravan (dual system)
– Ford F150
– Toyota Camry
– GM W Car
August 18, 2005 IMAC CRP 9
Team 1
Progress to Date
• Evaluated mini-shed tests to
establish refrigerant system direct
emissions
• Evaluating assembly plant “noise
factors” regarding assembly of
system components free of
contamination, damage, etc.
August 18, 2005 IMAC CRP 10
Team 1
2006 Plan
• Develop SAE Standard for
component and system mini-shed
test
Develop SAE Standard for reclaim
procedure to determine actual
vehicle charge level
Evaluate new low emissions
technologies per standard
August 18, 2005 IMAC CRP 11
Team 1
Description of Technologies
• Improved crimps
• Improved fittings
• Compressor shaft seal and body seals
• Hose permeation
• Material integrity-tubing
• Reduced number of joints
• TXV
• Transducer/switches
• Service valves/caps
• Manufacturing/Assembly specifications
• Leakage Test Procedure
• Robust Manufacturing/Assembly Procedures
August 18, 2005 IMAC CRP 12
Team 2
System Efficiency
• Goal:
– Improve system COP by 30% over the
enhanced R134a system that was
demonstrated in the SAE Phase 1
Alternative Refrigerant Cooperative
Research Program (ARCRP)
– Demonstrate equivalent performance
August 18, 2005 IMAC CRP 13
Team 2
Deliverables
• Demonstrate COP improvement on a System Test
Stand
• Demonstrate equal performance in a Vehicle Tunnel
• SAE J Standard for Measurement of System COP
using the System Test Stand Approach
• SAE J Standard for Annualized Climate Calculation of
System Power Loss
• Relative Cost / Benefit Analysis:
– Cost will be relative on a 1-10 scale
– Benefit will be COP improvement over the
enhanced R134a ARCRP system
August 18, 2005 IMAC CRP 14
Team 2
2005 Plans
• System Stand:
– Improved sub-cooling control (condenser)
– Improved superheat control (evaporator)
– Improved compressor efficiency
– Internal (suction/liquid) heat exchangers
• Vehicle:
– Sub-cooling and superheat algorithm
development
– A/C performance demonstration
August 18, 2005 IMAC CRP 15
Team 2
2006 Plans
• System Stand:
– Next generation condensers (pending availability)
– Next generation evaporators (pending availability)
– Alternative compressor designs (pending availability)
– “Best of the Best” combination
• Vehicle:
– Continue system development
– A/C performance demonstration
• Develop J Standards
• Develop Cost/Benefit Matrix
August 18, 2005 IMAC CRP 16
Team 2
Progress to Date
• Condenser sub-cooling control study shows
potential for 20-30% improved COP at low
loads (achieving control in a vehicle system is
an open issue)
• Evaporator superheat control study shows
potential for 20% improved COP at low loads
• Improved efficiency compressor study shows
potential for 15% improved COP (climate
weighted)
• Achieving the 30% improvement goal is
promising but the individual effects may not be
additive
August 18, 2005 IMAC CRP 17
Team 3
Vehicle Load Reduction
• Goal:
– Demonstrate vehicle level
technologies that reduce the
cooling load by 30%
August 18, 2005 IMAC CRP 18
Team 3
Progress to Date
• Tested the impact of various technologies on soak
temperatures
– Power ventilation device
– Solar reflective glazing
– Lightweight insulation
– Sunscreen for windshield
• Plan to test additional technologies
– Lightweight seats
– Solar reflective paints
• Developing a computer model at the National Renewable
Energy Lab (NREL) to estimate a technology’s impact on
time to comfort and power consumption
August 18, 2005 IMAC CRP 19
NREL vehicle Model
Qsolar
CAD
Tamb
Wcomp
Tair
Tmass Solar
Cond Glazing
Qevap Radiation
Condenser Air Cabin
Expansion Device
(Orifice Tube)
MOTORElectric-Driven
Compressor
Conditioning Thermal/Fluid
Alternator
Front-End
Generator
Air Flow
Accumulator /
Evaporator
Dryer
Evaporator Air Flow Thermal
(Outside Air or Recirc.)
Vehicle
Comfort
Fuel
Economy &
Emissions Cooling Capacity Occupant
& Thermal
A/C Power Comfort
August 18, 2005 IMAC CRP 20
Team 3
Deliverables
Procedure for evaluation of technology
Develop a ranking of approximate
cost/benefits for various technologies
• Evaluation of technologies in laboratory and
field
Demonstration vehicle for 2006 Phoenix
Meeting
Communication and education materials
August 18, 2005 IMAC CRP 21
Team 4
Reduction in Refrigerant
Loss During Servicing
• Goals:
– Evaluate and Recommend Improvements for
Service Tools, Equipment (New or Revised
Standards) and Service Procedures
– Identify, Quantify and Propose Remedies for
Refrigerant Losses at Service, Vehicle End of
Life
– Quantify and Address Losses from One-Way
Refrigerant Containers
– Produce Educational Materials and Conduct
Outreach to Reduce Refrigerant Emissions
August 18, 2005 IMAC CRP 22
Team Four – Service
Progress & Plans
1. Leak detection tools, procedures
– Writing standards for next
generation of tools
– Detection at 4 grams per joint/year
(Current standard 14 grams)
– Probe distance 3/8” (now ¼”)
– ‘Real world’ testing for standard
August 18, 2005 IMAC CRP 23
Team Four – Service
Progress & Plans
2. Service equipment, procedures
– Testing has shown that current
recovery equipment/procedures
leaves refrigerant in system
– Developing standard for next
generation of equipment
– Different recovery procedures
needed for different types of
systems
August 18, 2005 IMAC CRP 24
Team Four – Service
Progress & Plans
3. Flexible coupled hose assemblies
– Conduct lab testing to evaluate field
coupled assemblies for leakage
– Develop a cost-effective means of
field evaluation of assemblies
August 18, 2005 IMAC CRP 25
Team Four – Service
Progress & Plans
4. Analytical tool to evaluate
service procedures
– SAE Service Technology Group
Activity
• Focus on leak detection; diagnosis
5. Refrigerant mass balance
– Data collection to identify and
quantify the sources of all lifetime
R-134a emissions
August 18, 2005 IMAC CRP 26
Team Four – Service
Progress & Plans
6. Vehicle end of life
– Partnership with Automotive
Recyclers Association
– Raise awareness in this sector
– Develop strategies to improve
vehicle EOL refrigerant recovery
August 18, 2005 IMAC CRP 27
Actual/Forecast Funding vs. Original Plans
• Original 2004 announcement: “over $3 million in
cash and in-kind contributions”
• Program on track to surpass initial funding plan
$ 000’s EPA Industry In-Kind Total
Funds Funds Industry
CY 2004 60 60
CY 2005 370 560 900+ 1,830
CY 2006 370? 560? 900+ 1,830
Total 740 1,180 1,800 $3,720
August 18, 2005 IMAC CRP 28
Status After One Year
• All 4 teams are operational and
making progress
• Industry participation is high
• The program is on track to meet
scope, funding and technical
targets
August 18, 2005 IMAC CRP 29