Automotive Engineering - March 2016 - 12
TECHNOLOGY REPORT
System shown in heat pump mode
3-Way
Valve #1
2-Way Valve
& Orifice
Battery
Accu
Comp
Evap
Outside
Cond.
PTC HTR
Motor
&
Inverter
Chiller
2-Way
Valve
Inside
A/C TXV Cond
3-Way Valve #2
Kia Soul EV's switching valves bypass evaporator and direct hot liquid
refrigerant through under-dash inside condenser.
engine-off A/C cooling storage from secondary loop can be
sized to exceed 10 minutes. Developing a system for thermal
storage of heat for an EV is an obvious area for study, and research in that area reportedly will begin when funding, perhaps from a UN agency, becomes available.
The use of a water-antifreeze secondary loop also simplifies
the plumbing in vehicles with rear HVAC. Instead of high-pressure refrigerant lines, the system can use lower-cost heaterlike lines and hoses.
Because the greatest gains are in A/C, a team of researchers
looked at large population areas where the climate includes a long
cooling season. India, the example chosen, has winter temperatures of 20-25°C (68-77°F) in the mainland southeast, and long
hot and humid warm seasons. By taking this geographic example,
it could be seen if an optimized secondary loop A/C system could
match or exceed the efficiency of a direct expansion system.
The question and accompanying research was presented at
TMSS by Sangeet Kapoor and Prasanna Nagarhalli of Tata
Motors, and Timothy Craig and Mark Zima of Mahle's Delphi
Thermal. They worked with refrigerant scientist James Baker and
Dr. Stephen Andersen, retired EPA climate issues executive and
now research director of IGSD (Institute for Governance and
Sustainable Development), a non-governmental organization.
Refrigerant savings
Secondary loop is tough to package, adding a refrigerant-tocoolant heat exchanger/chiller, the pump to circulate the coolant, and extra piping. However, there is a 20% reduction in
refrigerant, which results in a significant cost saving if it's
R-1234yf. Using R-152a, because it is very low in cost, saves
even more. The coolant mixture used was 30% antifreeze, 70%
purified water, chosen for heat transfer efficiency.
A dynamometer test program looked at COP (Coefficient of
Performance) for the secondary loop, running it through a complete Federal Test Procedure (FTP) at 28°C (82°F), the New
European Drive Cycle (NEDC) at 28°C and an SCO3 cycle, the supplemental EPA cycle for A/C operation, which is run at 33°C (91°F).
12 March 2016
The tests were run with (1) no A/C, (2) continuous A/C with the
cabin soaked to ambient temperature, (3) with the A/C compressor disengaged at idle, and (4) on acceleration. Although there
was a modest improvement with the compressor stopped at idle,
the combination with the disconnect-on-acceleration, taking
greater advantage of the inherent thermal storage, produced dramatic fuel-economy improvements on all three cycles. The numbers: 6.5% on the FTP, 11.5% on the NEDC, and 12.5% on the SCO3.
R-152a has a global warming number below 150, so it is lower than international regulatory limits. Although this is higher
than R-1234yf's under 10, unlike R-1234yf it does not produce
TFA (trifluoroacetic acid, a plant growth inhibitor) as a degradation product, although currently not regulated.
The compressor with a circuit reversal to operate as a heat
pump, providing heat for the passenger compartment, is superior in a secondary loop because it also provides engine/
EV-off heat from the thermal storage. Even a half-way step-
heat pump in a direct expansion system-has demonstrated
value for an electric drive vehicle, where conventional electric
heating (resistance or Positive Temperature Coefficient) can
sharply reduce winter driving range. The heat pump is much
more efficient than conventional heating.
Nissan, Kia EVs
Both the Nissan Leaf and Kia Soul EV offer direct expansion
heat pump systems, presently using R-134a systems like the
companies' gasoline-engine cars, but with R-1234yf on the
horizon. There is a baby step into secondary loop: a waterantifreeze chiller circuit for cooling EV electronics, and Kia
estimates a 27% improvement from the heat pump in electrical heating efficiency over the winter temperature range.
Conventional (resistance and Positive Temperature
Coefficient) heating has a major effect on EV range in winter.
A study with various sizes of cars, reported at TMSS by Dr.
Gregor Homann of Volkswagen AG and Prof. Jurgen Kohler of
the University of Brunswick, showed a loss of 20-50% with
conventional electric heating. The greatest drop, not surprisingly, was suffered by the smallest vehicle, which has the
smallest battery pack, in testing at -7°C (+19°F).
Heat pumps have a positive COP in ambient temperatures
starting from above -15 to -18°C (0 to +5°F). They approach
2.8-3.5 at 10°C (50°F), the COP depending on refrigerant used
and pump design. So although the heat pump makes a significantly positive contribution at moderately cold temperatures, in
really cold weather conventional electric heating still is needed.
The heat pump might draw heat from warmer sources than
ambient air, such as EV electronics, motor, and the battery
pack. But these would require packaging a sophisticated ducting system and can make only minor contributions, if any, at
low ambient temperatures. In many areas, however, the ambient temperatures during heating seasons are sufficiently high
to make the heat pump a valuable addition for both EVs and
even many fuel-powered vehicles.
Paul Weissler
AUTOMOTIVE ENGINEERING
Automotive Engineering - March 2016
Table of Contents for the Digital Edition of Automotive Engineering - March 2016
Automotive Engineering - March 2016
Contents
What’s Online
Editorial: Mainstreaming hybrids and EVs
Rethinking the route to lower-cost fuel cells
Technology Report
Secondary loop and heat pump climate control under evaluation once more
OTA reflashing: the challenges and solutions
3D-printed high-temperature ceramics
Multi-material structures move mpg upward
Cars poised to become ‘a thing’
Agility training for cars
SAE 2016 World Congress Preview
Global Vehicles
2017 Pacifica is first hybrid minivan, rides on all-new FCA platform
Prius is re-engineered on Toyota New Global Architecture
2017 Porsche Boxster loses cylinders, gains power, adds frugality
2016 Mini Clubman’s torque-vectoring AWD system designed to give 2wd efficiency
Product Briefs
Companies Mentioned, Upcoming, Ad Index
Q&A
Automotive Engineering - March 2016 - Intro
Automotive Engineering - March 2016 - Automotive Engineering - March 2016
Automotive Engineering - March 2016 - Cover2
Automotive Engineering - March 2016 - 1
Automotive Engineering - March 2016 - Contents
Automotive Engineering - March 2016 - 3
Automotive Engineering - March 2016 - What’s Online
Automotive Engineering - March 2016 - 5
Automotive Engineering - March 2016 - Editorial: Mainstreaming hybrids and EVs
Automotive Engineering - March 2016 - 7
Automotive Engineering - March 2016 - Technology Report
Automotive Engineering - March 2016 - 9
Automotive Engineering - March 2016 - Secondary loop and heat pump climate control under evaluation once more
Automotive Engineering - March 2016 - 11
Automotive Engineering - March 2016 - 12
Automotive Engineering - March 2016 - 13
Automotive Engineering - March 2016 - OTA reflashing: the challenges and solutions
Automotive Engineering - March 2016 - 15
Automotive Engineering - March 2016 - 3D-printed high-temperature ceramics
Automotive Engineering - March 2016 - 17
Automotive Engineering - March 2016 - Multi-material structures move mpg upward
Automotive Engineering - March 2016 - 19
Automotive Engineering - March 2016 - 20
Automotive Engineering - March 2016 - 21
Automotive Engineering - March 2016 - Cars poised to become ‘a thing’
Automotive Engineering - March 2016 - 23
Automotive Engineering - March 2016 - 24
Automotive Engineering - March 2016 - Agility training for cars
Automotive Engineering - March 2016 - 26
Automotive Engineering - March 2016 - 27
Automotive Engineering - March 2016 - 28
Automotive Engineering - March 2016 - SAE 2016 World Congress Preview
Automotive Engineering - March 2016 - 30
Automotive Engineering - March 2016 - 31
Automotive Engineering - March 2016 - 2017 Pacifica is first hybrid minivan, rides on all-new FCA platform
Automotive Engineering - March 2016 - 33
Automotive Engineering - March 2016 - Prius is re-engineered on Toyota New Global Architecture
Automotive Engineering - March 2016 - 35
Automotive Engineering - March 2016 - 2017 Porsche Boxster loses cylinders, gains power, adds frugality
Automotive Engineering - March 2016 - 37
Automotive Engineering - March 2016 - 2016 Mini Clubman’s torque-vectoring AWD system designed to give 2wd efficiency
Automotive Engineering - March 2016 - 39
Automotive Engineering - March 2016 - Product Briefs
Automotive Engineering - March 2016 - 41
Automotive Engineering - March 2016 - Companies Mentioned, Upcoming, Ad Index
Automotive Engineering - March 2016 - 43
Automotive Engineering - March 2016 - Q&A
Automotive Engineering - March 2016 - Cover3
Automotive Engineering - March 2016 - Cover4
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