presentation - sanden hybrid compressor

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Sanden Hybrid Compressor

Udo SandtenGeorges El KhouryIEA WorkshopParisOctober 23-24, 2006

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Summary

Hybrid electric vehicleSanden hybrid compressor for HEVVehicle build upSystem controlComfort results Pull down comparisonImpact on fuel consumption

Conclusions

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Hybrid Electric Vehicle technology

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2

“Parallel” hybrid system

1-Internal combustion engine:

main energy source.

2-Electric motor/generator

Assists the ICE (downsizing)

Regenerative

Stop & Start

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Stop&Start can achieve up to 15% Fuel economyReduces emissions

Interface with Belt-driven MAC systems:- Economic mode: comfort issues- Comfort mode: reduces Stop&Start benefits

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0

5

10

15

20

25

30

35

0 200 400 600 800 1000 1200 1400

Time (s)

Tem

pera

ture

(°C

)

Passenger head T_CONV & ext contol

Passenger head T _ PRIUS I

The blown air temperature in ECON mode compared to an external control AC system

used in conventional vehicle.

The passenger head temperature in ECON mode compared to an external control AC system used in

conventional vehicle.

Impact on the passenger comfort*

Large variations (8 K) of the Louver air temperature ⇒ non negligible passenger discomfort.

For Ext. Ctrl. the variations are small despite the vehicle and engine regime variations.

PRIUS I (belt-driven compressor) vs. conventional vehicle

Belt-Driven Compressor

clutch

Engine

MAC compressor

belt

clutch

Engine

MAC compressor

clutch

Engine

MAC compressor

belt

1997

*Reference: Fiat Research Center

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Belt Drive plus Motor Drive : for Rapid Cool-downBelt Drive only : for Normal ConditionMotor Drive only : for Idle StopMotor Drive or Belt Drive: for Idle Stop & Low Heat Load

Belt Drive plus Motor Drive : for Rapid Cool-downBelt Drive only : for Normal ConditionMotor Drive only : for Idle StopMotor Drive or Belt Drive: for Idle Stop & Low Heat Load

SANDEN Hybrid Compressor Concept

Compact/Light Weight & Highly Efficient Hybrid Compressor

Compact/Light Weight & Highly Efficient Hybrid Compressor

Belt Drive forMain Scroll

Motor Drive forSeparate Scrollwith minimum

Mechanical Loss

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Power Input from Inverter

Rotor

Stator

Fixed Scroll

Belt Drive Scroll(75cc) Motor Drive Scroll(15cc)

Sanden Hybrid Compressor section view

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Sanden Hybrid Compressor specificationSanden Hybrid Compressor specification

MODEL NAME HBC75115

TYPE 2 SCROLL HYBRID

BELT DRIVEN 75cc/rev.

DISPLACEMENTMOTOR DRIVEN 15cc/rev.

BELT DRIVE 9,000rpm*MAXIMUM ALLOWABLE

CONTINUOUS SPEED MOTOR DRIVE 6,000rpm*

BELT DRIVE 12,000rpm*MAXIMUM DOWNSHIFT

SPEED MOTOR DRIVE N/A

REFRIGERANT HFC-134a

OIL SE-10Y

MOTOR DC BRUSHLESS MOTOR

MASS 9Kg*

*Reference Only

Two available voltages 42 and 144 Volts

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Sanden Hybrid Compressor in a MPV vehicle

Targets of the project:

⊕ Build up a fully functional A/C system in a drivable vehicle.

⊕ Ensure thermal comfort during Stops and during regular pull-down tests.

⊕ Investigate the possible fuel consumption advantage in a prototype installation.

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Vehicle build up in Sanden Technical Center

• 1,6 FSI vehicle.

• 42 V type hybrid compressor.

• Drivability of the car on normal road.

• The AC control works in automatic mode or in manual mode.

• Original PWM signal of the car is used as an input to the Hybrid Compressor controler. The original compressor (Sanden PXE16) is externally-controlled by “Klimatronic“.

• The input to the Hybrid Compressor controller is a PWM 12V with 400Hz and duty ratio from 0 to 100%.

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Installed additional Parts 42V Generator

• The necessary power for the electric part of the Hybrid compressor was provided by a 42 V generator (1,6 kW from Bosch).

• Installed instead of the standard generator.

DC/DC-Converter• All of the car function stays on 12V.• A DC/DC-Converter42V to 14V supplies the power and charges the 12 V battery. (average efficiency = 95%)

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Installed additional Parts 36V Battery

• A 36V battery is installed in addition to the 12 V battery.

• Location same as 12 V battery.

• The battery used is a lead-gel type.

• 36V battery (2.2Ah) is sufficient to run the electric compressor (0.5kW of electrical power) for at least 5 minutes.

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Control of the Sanden Hybrid Compressor (HBC)

Blockdiagram of HBC control

PWM-Signal

Suction Pressure

HBC controller

E-Motor

E-M Clutch

Hybrid Compressor

Engine rpmMechanical drivenElectrical driven

42 V Generator

Regulator36 V

Battery

12 V Battery

DC/DC converter

To existent 12V system

42 V PWM

12 V

Bat. Charge 36V

Bat. Charge 12V

Disch. pres.

IPU for HBC or

CAN

CAN

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Control Flowchart for the tests

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Control Result

first phase: EC increases RPM, second phase: EC off and clutch cycling,third phase: Clutch on and EC added.

Result: Head temperature nearly constant

Ps

C Inv

Av Louver

T Eva out Phi

T Av head

T Amb

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15

3,9

4

4,1

4,2

4,3

4,4

4,5

00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00

time [min:s]

Pre

ssu

re [b

ar]

abs.

120

160

200

240

280

320

360

PW

M S

igna

l [m

A]

ps hybridps PXEPWM Hybrid

PXE 40kph/Hybrid 23kph 20°C amb.temp.

Ps HBC

PWM HBC

PWM Series

Ps Series

PXE 40kph/Hybrid 23kph20°C amb.temp.

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9

11

13

15

17

19

21

23

25

00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00

time [mm:s]

Tem

pera

ture

[°C

]

toL2 hybridAV Head hybrid

Temp Eva HBC Temp Eva

Series

Av Temp Head HBC

Av Temp Head Series

General Controllability Result under steady state (20°C)

Higher Stability with the Hybrid compressor

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10

12

14

16

18

20

22

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0 200 400 600 800 1000 1200

Zeit Sekunden

mitt

lere

Kopfr

aum

tem

p. °

C

0

20

40

60

80

100

120

140

Ges

chw

ind

igke

it km

/h

Geschwindigkeit

mit Start/Stopp

ohne Start/Stopp

Idle/Stop function

• Idle/stop possible with manually engine off and manually engine on.

Purple curve: original AC system with the engine is always on, No Idle/Stop.Blue curve: vehicle with original belt-driven compressor and Idle/Stop strategyRed curve: Cooling is provided by the electric part of the Sanden Hybrid Compressor. Mechanical compressor is switched off.

30°C Ambient, no solar load, fresh air mode

Louver T° fluctuations improved from ±4°C to ±2°C.

Veh

icle

spe

ed (k

m/h

)

Tem

pera

ture

(°C

)

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Pull-down comparison with the original compressor

0

10

20

30

40

50

60

70

80

0:00 0:05 0:10 0:15 0:20 0:25 0:30 0:35 0:40 0:45 0:50 0:55 1:00 1:05 1:10 1:15 1:20 1:25 1:30

Time [h,min]

Tem

per

ature

[°C

]AV Louver Hybrid AV Head Hybrid

AV Louver PXE AV Head PXE

PXE nominal HybridTime Speed AV Louver AV Head AV Louver AV Head[min] [kph] [°C] [°C] [°C] [°C]

15 32 10,1 28,8 11,7 30,130 32 8,1 25 9,85 2645 32 7,2 23,8 8,76 24,360 32 7 22,5 8,04 23,275 0 13,2 26,2 14,08 26,990 0 12,5 26,8 15,32 28,3

0

10

20

30

40

50

60

70

80

0:00 0:05 0:10 0:15 0:20 0:25 0:30 0:35 0:40 0:45 0:50 0:55 1:00 1:05 1:10 1:15 1:20 1:25 1:30

Time [h,min]

Tem

per

ature

[°C

]AV Louver Hybrid AV Head Hybrid

AV Louver PXE AV Head PXE

PXE nominal HybridTime Speed AV Louver AV Head AV Louver AV Head[min] [kph] [°C] [°C] [°C] [°C]

15 32 10,1 28,8 11,7 30,130 32 8,1 25 9,85 2645 32 7,2 23,8 8,76 24,360 32 7 22,5 8,04 23,275 0 13,2 26,2 14,08 26,990 0 12,5 26,8 15,32 28,3

•The Sanden Hybrid Compressor (HBC) shows similar performances tothe original Sanden belt-driven externally controlled PXE16 which is slightly better.

•After 90 min. Engine runs up due to Electricity deficit ⇒ decrease of louver T° with the PXE16.

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Compressor PXE16

Q=1,66 kW P=720 W

Vehicle Electrics

off: 280 W on: 600 W

Power Consumption

Electric Power Consumption

Vehicle Electrics

off: 280 W on: 460 W

Electric Power Consumption (HV)

DC-DC Converter

Efficiency 95 %

Belt Drive Mode Belt Drive Mode -- Series PXE16Series PXE16

EE--Motor Drive Mode Motor Drive Mode -- HBCHBC

12 V AlternatorEfficiency

off: 66 % on: 68 %

Electric Power Consumption (42V)

Combustion engine

off: 420 W on: 1890 W

Difference: 1190 W

Calc. fuel diff: 0,23 kg/h

Meas. fuel diff.: 0,28 kg/h

v = Idle nmot = 850 1/min Tamb = 30 °C Willans: 0,194 kg/h/kW

E-Comp in HBC

P=780W


off: 65 % on: 63 %

Combustion engine

off: 455 W on: 1850 W

Difference: 1395 W



A/C System Efficiency Chain (Idle)A/C System Efficiency Chain (Idle)

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A/C System Efficiency Chain (driving 40km/h)A/C System Efficiency Chain (driving 40km/h)

Compressor PXE16

Q=1,61 kW P=1070 W

Vehicle Electrics

off: 224 W on: 530 W

Power Consumption

Electric Power Consumption

Vehicle Electrics

off: 220 W on: 460 W

Electric Power Consumption (HV)

DC-DC Converter

Efficiency 95 %

Belt Drive Mode Belt Drive Mode -- Series PXE16Series PXE16

EE--Motor Drive Mode Motor Drive Mode -- HBCHBC


off: 55 % on: 62 %

Electric Power Consumption (42V)

Combustion engine

off: 405 W on: 2055 W

Difference: 1650 W



v = 40 km/h nmot = 2770 1/min Tamb = 30 °C Willans: 0,194 kg/h/kW

E-Comp in HBC

P=520W


off: 56 % on: 61 %

Combustion engine

off: 413 W on: 1645 W

Difference: 1233 W



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Fuel consumption difference (on-off) in kg/h at Idle

0,000

0,100

0,200

0,300

0,400

0,500

0,600

0 5 10 15 20 25 30 35 40 45

Ambient temperature °C

Gas

olin

e kg

/h

Series-PXE16

E-Comp of HBC

Fuel consumption dif ference (on-off) in kg/h at 40 km/h

0,000

0,100

0,200

0,300

0,400

0,500

0,600

0,700

0 5 10 15 20 25 30 35 40 45Ambient temperature °C

Ga

solin

e k

g/h

Series-PXE16

E-Comp of HBC

Mech. comp.

Fuel consumption difference (on-off) in kg/h at 80 km/h

0,000

0,100

0,200

0,300

0,400

0,500

0,600


Gas

olin

e kg

/h

Series-PXE16

E-Comp of HBC

mech. Scroll

Fuel consumption difference (on-off) in kg/h at 120 km/h

0,000

0,100

0,200

0,300

0,400

0,500

0,600

0,700


Ga

solin

e k

g/h

Series-PXE16

E-Comp of HBC

mech. Scroll

A/C Fuel consumption = f(ambient TA/C Fuel consumption = f(ambient T°°, kph), kph)

Reduction of the Additional Fuel Consumption up to 50%

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Advanced control: Drive Mode Select Optimization

Motor Drive mode can be widely used to reduce annual average power consumption.Motor Drive mode can be widely used to reduce annual average power consumption.

@1,500cc Class Vehicle

With Sun LoadWith Sun Load

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PowerMechanicalPowerCoolingCOP MACdrivenBelt =

PowerElectricalPowerCoolingCOP MACdrivenlyElectrical =

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

2 3 4 5 6 7 8 9 10

Pressure ratio

CO

P

COP electrical+inverterCOP electrical Sdn15ccCOP belt-drivenPolynomial (COP belt-driven)

COP comparison between E-driven and belt-driven compressors

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1 2 3 4 5 6 7 8 P ratio

Mean Electricity Production efficiency = 70%CO

P

4

Electrical compressor

1- Engine OFF

2- Low thermal load

3- high acceleration

4- PID control

PowerMechanicalICEPowerCoolingCOP MACdrivenBelt =

PowerMechanicalICEPowerCooling

COP generationelectricalMACdrivenlyElectrical η=

EC 15 cc

COP Electric compressorCOP Electric compressor + inverterCOP Belt driven compressor Mechanical compressor

1- High Thermal load

2- ON/OFF control

3- Assisted by EC for fast cool-down

MECA75cc

Advanced control: Drive Mode Select Optimization

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Power consumption improvement depends on the Vehicle driving condition and the Weather condition. (12% in city mode up to 36 % on Highway)

Mean difference 0.043 L/100km ⇒ 6.5 L/year* and 1 gram CO2/km.

*15000 km/year basis

Fuel Consumption Improvement-in terms of Annual Average Fuel Consumption

0.602

0.555

0.359

0.316

0.206

0.165

0.0

0.4

0.8

City ModeCity Mode

Okinawa

Tokyo

Sapporo(A)

(B)

Fue

l C

onsu

mpt

ion(

L/1

00K

m) 0.602

0.555

0.359

0.316

0.206

0.165

0.0

0.4

0.8

City ModeCity Mode

Okinawa

Tokyo

Sapporo(A)

(B)

Fue

l C

onsu

mpt

ion(

L/1

00K

m)

0.194

0.141

0.120

0.077

0.074

0.038

0.0

0.1

0.2

Highway ModeHighway Mode

Okinawa

Tokyo

Sapporo

(A): Idle Stop Only

(B): Mode Selection

(A) (B)

Fue

l C

onsu

mpt

ion(

L/1

00K

m)

0.194

0.141

0.120

0.077

0.074

0.038

0.0

0.1

0.2

Highway ModeHighway Mode

Okinawa

Tokyo

Sapporo

(A): Idle Stop Only

(B): Mode Selection

(A) (B)

Fue

l C

onsu

mpt

ion(

L/1

00K

m)

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Conditions for the Simulation

【Vehicle and A/C System】

Japanese 1,500cc class car with original A/C System was used to make basic power consumption data & fuel consumption data for the simulation.

【Conditions for the A/C System Operation 】

Vehicle driving duration: 1 hr/day

Operation timing:Daytime 50%,Night time:50%

A/C Off Ambient: Less than 13 ℃ w/o sun load, Less than 18 ℃ w/ sun load

Radiation(Sun Load)：0.9KW

Air flow rate：AUTO(Sanden STD)

In car temp.setting：25℃(AUTO)

Evaporator outlet temp.setting：5℃ (for preventing the evaporator icing)

Air intake：Fresh(Outside air)

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Annual Average Power ConsumptionAnnual Average Power Consumption

Annual Average Power Consumption

Test Data of A/C System

Pow

er C

onsu

mpt

ion

Vehicle Speed

Ta City Mode

走行条件設定

IDLE49%

40 km/h40%

80 km/h11% IDLE

49%40 km/h

40%

80 km/h11% IDLE

49%40 km/h

40%

80 km/h11%

City Mode

IDLE4%

40 km/h13%

80 km/h43%

120 km/h40% 80 km/h

43%

120 km/h40% 80 km/h

43%

120 km/h40%

Highway Mode

Driving Condition

日付

期間：'76～97年出典：丸善気象年表Ⅰｱﾒﾀﾞｽ1998

-10-50510152025303540

0 30 60 90 120 150 180 210 240 270 300 330 360

気温℃ 那覇

東京

札幌

Days

-10-50510152025303540

0 30 60 90 120 150 180 210 240 270 300 330 360

那覇

東京

札幌

-10-50510152025303540

0 30 60 90 120 150 180 210 240 270 300 330 360

那覇

Tokyo

SapporoAm

bien

t Tem

p.de

gree

C

Weather Data for 20 Years

Max./Averaged Temp.

Sunshine Duration

Annual Average Fuel Consumption

Fuel consumption

Fuel

con

sum

ptio

n

A/C Power Requirement

IDLE

40km/h

60km/h

(@Test Vehicle)

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Conclusions

A Sanden Hybrid Compressor could be installed in a mass production vehicle.

⊕ The tests on Idle/Stop-function, the Hybrid Compressor is able to maintain the comfort in the vehicle.

⊕ The Hybrid compressor pull-down characteristic is similar to the original Sanden externally-controlled PXE16.

When using the Hybrid Compressor a fuel consumption advantage could be achieved during driving operation.

Car application: The Sanden Hybrid Compressor has been introduced by Honda on the New HEV Accord (USA).

presentation - sanden hybrid compressor

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