Development of Carbon Dioxide (CO2) Applied

Refrigeration System

<Compatibility of cooling performance and safety functions

with the use of electrically controlled expansion valve>

Torahide Takahashi
CalsonicKansei Corporation

2000 1
 Contents of Presentation

1. Introduction
2. System Components & Specifications
3. Control Method
4. Results of Vehicle Tests
5. Summary
6. Future Activities

2000 2
 1. Introduction
In the development of CO2 refrigeration systems, the challenge to
be met is to assure the cycle safety and the required cooling
performance at the same time,
time due to the higher refrigerant gas
pressure & temperature at the compressor outlet. (Compared with
HFC134a systems)

In order to meet this challenge, the CO2 refrigeration system we

have developed uses an electrically controlled expansion valve.

With the introduction of this electrically controlled valve,

our system has successfully achieved the required
cooling performance and safety levels.

2000 3
2. System Components & Specifications

2-1 Components
Gas cooler
Internal heat exchanger ‡C ‡B ‡A
10

Pressure
(MPa)
Relief valve
‡C ‡B Pressure SW
Electrically controlled
expansion valve Pressure sensor 3.5 ‡E ‡D‡@
‡E ‡A Temperature 0•‹C31•‹C
sensor
Enthalpy (J/kg)
‡D ‡@ Mollier chart

CO2 Refrigeration
Accumulator System
Evaporator
Compressor
2000 4
 2-2 Specifications of components
HFC134a system
variable displacement type,
Compressor swash plate
Displacement : 184 cc/rev
CO2 system
fixed displacement type,
swash plate
Displacement : 30 cc/rev

Multi-flow type Multi-flow type

Gas cooler Core size (mm): 690W x 372H x 19D Core size (mm): 702W x 374H x 27D
Frontal area: 0.257 m2 Frontal area: 0.262 m2

Laminate type Multi-flow type

Evaporator Core size (mm): 235W x 265H x 64D Core size (mm): 265W x 213H x 88D
Frontal area: 0.0628 m2 Frontal area: 0.0553 m2
Internal Double tube serpentine type
heat Size: 19(dia) x 4 connections
exchanger

Expansion Thermal expansion valve Electrically controlled

valve expansion valve

2000 5
2-3 Electrically controlled expansion valve
Compressor outlet

•¢P (Pin•]Pout)
pressure & temperature
Up
Plunger Down
Solenoid

OUT Smaller Duty Larger

Outlet pressure: Pout
Inlet pressure: Pin
a

Solenoid
IN b

applied
voltage
Main valve
Pilot valve Time
Piston

2000 6
 2-4 Vehicle installed condition
Evaporator (Passenger room)
Electrically
controlled
expansion valve

Internal heat
exchanger

Compressor
Gas cooler

2000 7
 3. Control
3-1 System control
Pmax Pressure limit
Compressor outlet pressure (Mpa)

Relief valve operation value

P4
Mechanical pressure switch operation value
P3
Compressor off value
on electric pressure sensor

on temparature sensor
P2

•ÛŒì•§Œä—̈æ
Compressor off value
Protection control zone
P1

Thermal limit
Expansion valve
control zone

P0
ance
rform
g pe one
olin rol z su re
Co cont w
s
pre ction
Lo ote e
pr zon
T0 T1 T2 Tmax
Expansion valve control zone
Compressor outlet temperature (•‹C)

2000 8
 3-2 Cooling performance control

Ambient sensor Gas cooler

Passenger room Engine

temperature revolution

PTC set value Internal heat exchanger

Control Accumulator
amplifier Pex Ps / Ts Pd / Td
Tex

Proper duty
value
Pe / Te
Clutch Compressor
Clutch Electrically controlled Evaporator
expansion valve

Intake air
temperature sensor
Evaporator back
temperature sensor

2000 9
 3-3 System protection control
(at gradual pressure & temperature rise)
Pmax
Compressor outlet pressure
(Mpa)

P4
P3
P2
Protection control zone
P1
P0 Gradual rise
Gradual rise
ling ance
Coo erform l zone
p ntro
co
T0 T1 T2 Tmax
Compressor outlet temperature (•‹C)

2000 10
3-3-1 Protection control at gradual pressure rise
Compressor OFF
Pressure (Mpa)

P2
Protection control zone
Rising ratio
determining
P1
Returning point
P0
Cooling performance control zone

100
valve opening

Amplifier spec. value

Expansion

ratio (%)

0
Opening ratio will increase until the pressure becomes
lower than the control returning value.
Time

2000 11
3-3-2 Protection control at gradual temperature rise
Compressor OFF
T2
Protection control zone
Temperature

Rising ratio
determining
T1
Returning point
(•‹C)

T0

Cooling performance control zone

100
Expansion valve

Amplifier spec. value

ratio (%)
opening

0
Opening ratio will increase until the temperature
becomes lower than the control returning value.
Time

2000 12
 3-4 System protection control
(at rapid pressure & temperature rise)
Pmax
(Mpa)
Compressor outlet pressure

P4
P3
P2
Protection control zone
P1
P0
Rapid rise

ling nc e Rapid rise

a
Coo rform l zone
pe ntro
co
T0 T1 T2 Tmax
Compressor outlet temperature (•Ž )

2000 13
3-4-1 Protection control at rapid pressure rise
Pressure (Mpa) Compressor OFF
P2
Protection
control zone
P1
Returning point
P0
Cooling performance
control zone
valve opening

100
Expansion

ratio (%)

Amplifier spec. value

0
Time

2000 14
3-4-2 Protection control at rapid temperature rise

Temperature (•‹C) T2
Compressor OFF
Protection
control zone
T1
Returning point
T0
Cooling performance
control zone
valve opening

100
Expansion

ratio (%)

Amplifier spec. value

0
Time

2000 15
 3-5 System protection control
(at rapid engine revolution rise)
Engine revolution
Increase rate
(min-1)
determination

100
valve opening
Expansion

Amplifier spec. value

ratio (%)

0
Time

2000 16
 3-6 Other protective functions

1) Evaporator anti-freezing function

2) Refrigerant leak protection

3) Compressor protection at its

maximum speed operation.

2000 17
 4. Vehicle Cool Down Test Results
<Ambient conditions>
Temperature: 40•‹C
Humidity : 50% CO2
Sun load: 1,050 W/m2 HFC134a
50
40 km/h 100 km/h Idling
Temperature (•‹C)

40
Room Average
30

20
Vent Outlet

10

0
0 10 20 30 40 50 60 70
Time (min)

2000 18
 5. Summary
1) Same cooling performance level as the
HFC134a system was achieved due to
precise control of electrically controlled
expansion valve.
2)Through the control on changing ratio of
pressure and temperature, our CO2
system expanded operational zone.
And our system reduced clutch on/off
frequency and improved drivability.

2000 19
 6. Future Activities

1) System weight reduction

2) System efficiency improvement
3) Further safety improvement

2000 20