The next generation A/C Compressor DOOWON Compressor

High efficiency R744 compressor

development for vehicle
Prof. Geon Ho Lee
P f Hak
Prof.
H k Soo
S Kim
Ki

(ghlee@doowon.ac.kr)
(kimhs@doowon.ac.kr)

VDA Alternative Refrigerant Winter Meeting 2008

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 DOOWON Companies for Automotive A/C system

The next generation A/C Compressor DOOWON Compressor

Doowon Climate Control Co.,Ltd

A/C System
Heat exchanger

Doowon Heavy Industry co. Ltd

Doowon Refrigeration Co.,Ltd

Compressor

HVAC
CC
Case

Controller

Pipe

Electric system

M
Mass
product
d t (1
(1.2
2 million/year)
illi /
)

Reciprocating
t
type
for
f B/C
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Fixed Swash Plate

t
type
(150cc,
(150
170cc)
170 )

Doowon Electronics Co.,Ltd

D
Development
l
t

Variable Swash

R744 Swivel

Pl t type
Plate
t
(90cc,
(90

J i t type
Joint
t

130cc, 160cc )

( DC28)

Electric Scroll
type
(DE27)

The next generation A/C Compressor DOOWON Compressor

CONTENTS
I.

Development
p
Environment

II. DC28 R744 Compressor

III. DC28 Performance Test
IV. DC28 Vehicle Test
V.

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DC28 Master Project Plan

I. Development Environment of DC28 R744 Compressor

The next generation A/C Compressor DOOWON Compressor

DC28
(R744 Compressor)
Broad development experience
Ability to develop the R134a
p
compressor

Match

Manufacturing Know-how
of Mass Production

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Innovative Engineering Company

as a R744 technical leader

II-1. DC28 R744 Compressor Specifications

The next generation A/C Compressor DOOWON Compressor

MODEL

DC28

Type

External Variable Displacement

Displacement

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

Max.

Weight

4.5kg

Max rpm
Max.

11 000 (9
11,000
(9,500-Continuous)
500 Continuous)

Clutch Type

Clutchless

Si
Size

105 220
105x220mm

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

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II-2. DC28 R744 Compressor Structure

The next generation A/C Compressor DOOWON Compressor

2.
External Fin
for cooling

1.
Resin Pulley
for weight
reduction
d ti

3.
Controller with
Control valve and
P-T Sensors

4.
Oil Separator
for low oil circulation ratio

5.
Swivel Joint Mechanism
for low friction loss and
hysteresis
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II-3. DC28 R744 Compressor Advantages External fins

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250

200
w/o Fins

Heat output
on the inner walls
: 600W
Air speed
on the outer walls

4 Fins

Housing T
Temp ()

Boundary Conditions

191
160
149

150

100

: 50km/h
50

0
w/o Fins

7 Fins
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4 Fins

7 Fins

II-3. DC28 R744 Compressor Advantages SJ mechanism

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Swash Plate

Swivel Joint

Mass Flow

200

50

Mass flow down

180
160

Mass flow up

45

Torque down

40

Torque up

35

Torque

120

25

80

20

60

15

40

10

20

0
0

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 [%]

No correlation between valve signal and

t
torque
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30

100

Torque [Nm]

Mass Flow [kg/h]]

140

Correlation between valve signal and torque

(2000 rpm))
7

II-3. DC28 R744 Compressor Advantages Control strategies

The next generation A/C Compressor DOOWON Compressor

DC28 compressor is
i having
h i two
t
control
t l strategies
t t i
Item

w/ Integrated controller

w/o controller

Same R134a system

y
control logic
g

Need to change
g the control logic
g

Figure

Control logic
g
1.
Advantages

2.
3
3.

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Simple Plug-In solution

No Change A/C ECU of R134a,
need
d only
l electric
l t i power
Safety mode
control discharge pressure
Discharge pressure signal output

1. Low cost
2. Compact size

Remarks

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

The next generation A/C Compressor DOOWON Compressor

Overall Efficiency
(=Theoretical Power/Real Power)

Volumetric Efficiency
100

100

90

90

Remarks
Test Conditions

16%

70

R134a [Swash plate]

60
50
40
30

70

30%
60

1500

2000

2500

: 10

40

2. DC28(R744)

30

10

- Discharge Pressure
: 120 bar
- Suction Pressure

0
500

COMP. RPM

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- Suction Pressure
- Suction SH

50

10

: 15 bar
: 2 bar

R134a

20

1000

1. R134a
- Discharge Pressure

20

0
500

DC28 [R744]

80

OVE
ERALL EFFIC
CIENCY (%)

Result

VOLU
UMETIC EFF
FICIENCY (%)

DC28 [R744]
80

: 40 bar
1000

1500

COMP. RPM

2000

2500

- Suction Temp.
: 30

III-2. VDA Durability Test

The next generation A/C Compressor DOOWON Compressor

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 durabilityy test on Jan. 2007
- 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 System

The next generation A/C Compressor DOOWON Compressor

Type

Item

Vehicle

R744 A/C system

Type

SUV

Engine

2700 cc

HP

175ps

T/M

Auto

Compressor

DC28 External Variable type [DWHI]

Gas Cooler

Parallel Flow type [DCC]

p
Evaporator

Parallel Flow type

yp [DCC]
[
]

IHX

Co-axial type [DCC]

Accumulator

600 cc Al type [DCC]

PXV

Mechanical type [Obrist]

* Doowon Climate Control Co. install R744 A/C system in test vehicle
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IV-2. Vehicle A/C Pull Down Test with DC28 R744 Compressor
The next generation A/C Compressor DOOWON 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

Tem
mperature (()

50.0

Conclusion

40.0

Initial Cooling

30.0

: Better than R134a

Room Avg. (R134a)

Room Avg. (R744)

Driving Condition

20 0
20.0

: Similar to R134a

Vent Avg. (R134a)

Vent Avg. (R744)

10.0

Idle Condition
0.0
0

15

30

45

60

Time (min)

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75

90

: Better than R134a

IV-3. Bench Test with DC28 R744 Compressor

The next generation A/C Compressor DOOWON Compressor

Comparison of mechanical power and C.O.P.

C O P on the same cooling capacity at 2000rpm.
2000rpm
R134a A/C System : 160cc Internal Variable Swash Plate Type Compressor

Co
ooling Capa
acity (kW), Power (kW
W), COP

70
7.0
Cooling Capacity - R744

Cooling capacity

Cooling Capacity - R134a

6.0

Power - R744
Power - R134a

5.0

COP - R744

Conclusion

COP - R134a

4.0

On the same cooling capacity,

3.0

DC28 COP is superior than R134a in the

2.0

all test conditions.

1.0

C.O.P.

0.0

Evap.
Air Flow

Low

High
20/50%RH

Low

High
30/40%RH

Low

40/40%RH

Test Conditions (2000rpm)

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High

13

(Excluded 40 High load)

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

The next generation A/C Compressor DOOWON Compressor

Operating Conditions : SUV Car, In Dubai , T_amb 35 , A/C Controller 22 auto setting
120

3500

Highway

Idle

Highway

3000

100

Highway Condition

2500
80
2000

Ps

60

Ps set
Ps_set

1500

40

Current (mA)

PRESSURE ((bar), TEMP ()

Conclusion

City Mode

: Stable controllability
Idle Condition
: Stable controllability

1000

City Condition

20

500

: In spite of changing
0
0

1200

Discharge Pressure

2400

3600
TIME (sec)

Suction Pressure

Real value

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4800

6000

Suction Pressure_set

Target value

14

0
7200

A/C Signal

speed, suction pressure

had stabilized within
1.5 bar

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

The next generation A/C Compressor DOOWON Compressor

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

200

5,000

180

4,000

160

3,000
2,000

120

1,000

100

2.0 3.5 bar

80

-1,000
1 000

High pressure
Low pressure

60

ENG. RPM

PRE
ESSURE (bar), SPEED (kph)

Eng. rpm
140

-2,000

40

-3,000

20

-4,000

Vehicle speed
Ambient temp.

0
0

60

120

180

-5,000
240

TIME (sec)

Conclusion

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In spite of changing vehicle speed, the pressure difference between suction and discharge is 2.0~3.5bar
Thi pressure value
This
l can nott open PXV expansion
i valve.
l

15

IV-6. Vehicle Durability Test with DC28 R744 Compressor

The next generation A/C Compressor DOOWON Compressor

T
Target
t : 100
100,000
000 kkm with
ith SUV (2 cars))
22. Mar. 2007 ~ 18. Jul. 2007 (105 days, 1260 hrs) / UAE Dubai

No. 1 Vehicle
hi l

No 2 Vehicle
No.
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IV-6. Vehicle Durability Test with DC28 R744 Compressor

The next generation A/C Compressor DOOWON Compressor

60.0

120,000

38 53

100,000

40 0
40.0

80 000
80,000

Mileage : 100,000 km
(2007.07.18)
30.0

60,000
,

Amb. Temp. ()
Mileage (km)
20.0

40,000

10.0

20,000

0.0
07/3/22

0
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

Day (yy/mm/dd)
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07/7/10 07/7/20

Mileag
ge (km)

Tempera
ature ())

50.0

The next generation A/C Compressor DOOWON Compressor

Thank you for your interest.

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18