1. Improved HFC-134a Refrigerant Systems
Society of Automotive Engineers Improved Mobile Air Conditioning Cooperative Research Program
Improved HFC-134a Refrigerant Systems

2. 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

3. Current 27 Corporate Sponsors
Ineous Fluor
Japan Fluor Mfg Assoc
Manuli
Modine
Nissan
Parker Hannifin
Sanden
Schrader-Bridgeport
Solvay
TI Automotive
Toyota
Trelleborg
Viking Plastics
Visteon
Arkema (Autofina)
Audi
Behr  
BMW
DaimlerChrysler  
Delphi 
Denso 
DuPont 
Ford  
Fujikoki
General Motors
Goodyear
Honeywell  
August 18, 2005
IMAC CRP

4. Demonstration Vehicles
Project Goals
Team 4
Containment During
Service & Disposal
Team 1
50% Leakage
Reduction
IMAC Core
Team 2
30% Efficiency
Improvement
Demonstration Vehicles
2005/2006
Team 3
30% Load
Reduction
August 18, 2005
IMAC CRP

5. 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

6. Project Organization CORE GROUP Tier One Tier Two OEM Industry
Overall Project Management
Financial Oversight
Funding strategy
Educate management
CORE
GROUP
Tier One
Tier Two
OEM
Industry
SAE
Leakage
Efficiency
Vehicle Load
Service
Members:
Tier 1 suppliers
Tier 2 suppliers
OEM’s
MACS and Members
EPA
Refrigerant Suppliers
Other
Members:
OEM’s
Tier 1 suppliers
NREL
EPA
University’s
Other
Members:
OEM’s
Tier 1 suppliers
NREL
University’s
Other
Members:
OEM’s
Tier 1 suppliers
EPA
MACS and members
Other
Overall Technical Leadership
LCA & Cost Benefit Analysis
Sub-group Coordination
OEM Advisors GM
Ford
D-C
To advise in case of proprietary technologies
August 18, 2005
IMAC CRP

7. IMAC Project Teams 16 3 4 6 7 1 8 13 2 5 25 24 Team4 Team3 Team2 Team1
Reduction in refrigerant losses at service
Load Reduction Improved comfort
Improved Efficiency
Reduction in Leakage
Goals: 16 3 4 6
Others: 7 1 8 13
Tier1’s: 2 5
OEM’s: 25 24
Number of Team Members:
Service refrigerant loss Reduction
Vehicle Thermal Load Reduction
AC System Efficiency Improvement
Refrigerant Leakage Reduction
Team Name:
Team4
Team3
Team2
Team1
August 18, 2005
IMAC CRP

8. Team 1 Refrigerant Leakage Reduction
Goal:
Reduce HFC-134a Mobile Air Conditioning System refrigerant direct emissions by 50%
August 18, 2005
IMAC CRP

9. 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

10. 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

11. Team 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. Team 3 Vehicle Load Reduction
Goal:
Demonstrate vehicle level technologies that reduce the cooling load by 30%
August 18, 2005
IMAC CRP

19. 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

20. NREL vehicle Model CAD Solar Radiation Glazing Air Cabin Conditioning
Tamb
Qevap
Qsolar
Tair
Tmass
Wcomp
Cond
Solar
Radiation
Glazing
Air
Conditioning
Cabin
Thermal/Fluid
Front-End
Air Flow
Accumulator /
Dryer
Electric-Driven
Compressor
Condenser
Expansion Device
(Orifice Tube)
Evaporator
Evaporator Air Flow
(Outside Air or Recirc.)
MOTOR
Alternator
Generator
Thermal
Comfort
Vehicle
Fuel
Economy &
Emissions
Cooling Capacity
&
A/C Power
Occupant
Thermal
Comfort
August 18, 2005
IMAC CRP

21. 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

22. 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

23. Team Four – Service Progress & Plans
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

24. Team Four – Service Progress & Plans
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

25. 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

26. Team Four – Service Progress & Plans
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

27. 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

28. 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
Funds
Industry
In-Kind Industry
Total
CY 2004 60
CY 2005
370
560
900+
1,830
CY 2006
370?
560?
740
1,180
1,800
$3,720
August 18, 2005
IMAC CRP

29. 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