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Ancillary Load Reduction Task Overview Ancillary Load Reduction Task Overview John Rugh, Task Leader John Rugh, Task Leader Desikan Bharathan Desikan Bharathan Jason Jason Lustbader Lustbader Matthew Keyser Matthew Keyser Center for Transportation Technologies & Systems Center for Transportation Technologies & Systems National Renewable Energy Laboratory National Renewable Energy Laboratory August 2004 August 2004

Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

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Page 1: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Ancillary Load Reduction Task OverviewAncillary Load Reduction Task OverviewJohn Rugh, Task LeaderJohn Rugh, Task Leader

Desikan BharathanDesikan BharathanJasonJason LustbaderLustbaderMatthew KeyserMatthew Keyser

Center for Transportation Technologies & SystemsCenter for Transportation Technologies & SystemsNational Renewable Energy LaboratoryNational Renewable Energy Laboratory

August 2004August 2004

Page 2: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 3: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Demand for Fuels Outstrips SupplyDemand for Fuels Outstrips SupplyDomestic Production with Transportation Use (1970Domestic Production with Transportation Use (1970--2020)2020)

0

2

4

6

8

10

12

14

1970 1980 1990 2000 2010 2020

GAP

Source: Transportation Energy Data Book: Edition 19, DOE/ORNL-6958, September 1999, and EIA Annual Energy Outlook 2000, DOE/EIA-0383(2000), December 1999

Mill

ions

of B

arre

ls p

er D

ay

Domestic Oil ProductionHeavy Trucks

Automobiles

Light Trucks

Pas

seng

er V

ehic

les

Page 4: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Vehicle Ancillary Load ReductionGoal

To work with industry to reduce energy use for vehicle climate control by 50% in the short-term and 75% in the long-term while maintaining passenger thermal comfort and safety.

Page 5: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Cool Car - ApproachTo develop integrated analysis tools and testing to analyze advanced climate control systems for a diverse supplier base from a systems perspective (thermal comfort, fuel economy, tailpipe emissions)

Page 6: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 7: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Energy Used in Conventional Vehicle

Input100% (48.8)

Rolling5.0% (2.4)

Acc.2.8% (1.4)

Engine79.3% (38.6)

Aero.5.3% (2.6)

Driveline3.4% (1.7)

Braking2.5% (1.2)

21.3 city, 39 highway: 26.7 mpgge

w/AC10% (5.6)

Reduce Size of Existing AC SystemsWithout

AC

Energy Usage for Composite FTP & Highway Numbers in ( ) are MJ

Page 8: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Measured Insight and PriusFuel Economy Impacts from A/C

Page 9: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Measured Insight and PriusFuel Economy Impacts from A/C

53% increase in fuel use

43% increase in fuel use

Page 10: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Percent of Time AC UsedCooling + Demisting, 32.6%

1014

19

15

27

17

25

18

31

26

49

40

23

50

17

26

42

40

25

21

41

32

23

19

26

19

38

18

52

33

2024

37

28

50

3033

3225

23

26

69

41

57

2129

58 43

43

6

15

27

17

25

18

31

26

49

40

23

50

17

26

42

40

25

21

41

32

23

19

26

19

38

18

52

33

2024

37

28

16

50

3033

3225

23

26

69

41

57

28

21

2129

58 43

43

6

Percent of TimeAC for Cooling

+ Dehumidification

6.3 to 17.917.9 to 19.619.6 to 22.922.9 to 25.125.1 to 25.925.9 to 28.428.4 to 32.132.1 to 37.837.8 to 41.441.4 to 49.249.2 to 57.357.3 to 69.3

Page 11: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Modeled U.S. Mobile AC Fuel Use7.0 billion gallons used for air conditioning annually

Equivalent to 5.5% of the national fuel use, or ~9.5% of the imported crude oil!

1014

19

7

37

78

64

9

187

43

735

179

17

127

15

238

66

109

229

273

61

52

167

22

40

12

219

17

85

144

86186

21

118

176

9575

142242

26

68

68

251

753

76730

216 86

167

1

7

37

78

64

9

187

43

735

179

17

127

15

238

66

109

229

273

61

52

167

22

40

12

219

17

85

144

86186

21

118

86

176

9575

142242

26

68

68

251

753

19

61

76730

216 86

167

1

Million GallonsCooling &

Dehumidification

1 to 1717 to 2626 to 5252 to 6868 to 7878 to 8686 to 142142 to 176176 to 216216 to 242242 to 730730 to 753

Page 12: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

European Union and Japan:Fuel Used for Cooling and Demisting

EU: 6.9 billion liters (1.8 billion gallons, 16 billion kg CO2) used for air conditioning annually, Equivalent to 3.2% of the total fuel use

Japan: 1.7 billion liters (0.5 billion gallons, 4 billion kg CO2) used for air conditioning annually, Equivalent to 3.5% of the total fuel use

United Kingdom

Turkey

Switzerland

Sweden

Spain

Romania

Portugal

Poland

Norway

Netherlands

Japan

Italy

Ireland

Hungary

Greece

Germany

France

Finland

Denmark

Czech Republic

Bulgaria

Belgium

Austria

Million GallonsCooling &Dehumidification

8 to 12

12 to 14

14 to 16

16 to 23

23 to 25

25 to 41

41 to 53

53 to 75

75 to 258

258 to 303

303 to 450

450 to 450

Page 13: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Why So Much Fuel for A/C?

150 Watts

Metabolic Heat Generation

A/C Cooling 6000 Watts!

Page 14: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Systems Approach

Traditional Approach - Equipment Emphasis

EFFICIENT EQUIPMENT

EFFICIENT DELIVERY

VERSUS

REDUCE LOAD

Decreases in load have a larger impact on fuel use due to equipment and delivery losses.

Page 15: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 16: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Collaborative Projects with Ford

Page 17: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Lincoln Navigator Project

• Examine technologies to reduce solar heat gain– Improve thermal comfort– Improve fuel economy– Reduce emissions

Page 18: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Ford L/N Industry Partners• Shades, reflective and absorptive

– BOS Automotive• Window glazings, Solar Reflective

– PPG – Guardian Automotive

• Roof reflective films– 3M: Infrared reflective, visibly reflective

• Patterned glass– Solutia: VancevaTM Design Pattern

• Thermal insulation– 3M: ThinsulateTM– Lawrence Berkeley Lab gas filled panels

• Vehicle testing and data analysis– NREL

BOSBOS

Page 19: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Temperature Reduction Variable

% of maximum possible temperature reduction

All results referenced to (Tcabin- Tambient)baseline = 20°C

( )( )baselineambientaircabin

modifiedambientaircabin 1TTTT

−−

−=θ

Theta = 1, Tcabin,modified = Tambient

Theta = 0, Tcabin,modified = Tcabin,BL

Page 20: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Navigator ResultsSummary of Technologies

-10

0

10

20

30

40

50

60

70

80

90

100

Al Foil

Cab

inAl F

oil W

indow

sAl F

oil D

oors

and R

oof

Passiv

e Ven

t

Active

/Clos

ed V

ent 5

0 cfm

Reflec

tive S

hade

s

Infrar

ed R

eflec

tive W

indow

s

3M V

isibly

Refl

ectiv

e Roo

f Film

Panel

Insula

tion

Black A

bsorb

ing S

hade

s

Thet

a (%

)

Theta = 1, Tcabin,modified=TAmbient

Page 21: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Estimated Fuel Economy Impacts(L/N Cabin Results)

Technology Compressor Power Fuel Economy ImprovementPassive vent 34.0% 6.6 %, 1.1 mpgActive vent 24.0% 4.8 %, 0.76 mpg

Shades 14.3% 2.9 %, 0.45 mpgRoof film 9.4% 1.9 %, 0.3 mpg

Reflective Windows 11.4% 2.3 %, 0.36 mpgInsulation 6.6% 1.3 %, 0.22 mpg

Page 22: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 23: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Collaborative Projects with DaimlerChrysler

DAIMLERCHRYSLER

Page 24: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

DaimlerChrysler Grand Cherokee Test Project

• Examine technologies to reduce solar heat gain• Data for validating integrated modeling tools

Page 25: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

DaimlerChrysler Industry Partners

• DCX - European Jeep Grand Cherokee– U.S. glazings installed prior to delivery

• PPG - Sungate® windshield, door sidelites• 3M - Thinsulate® acoustic/thermal insulation• NREL – Vehicle testing and data analysis

DAIMLERCHRYSLER

Page 26: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Integrated ModelingCAD

SolarRadiation Glazing

ThermalComfort

AirConditioning

Cabin Thermal/Fluid

Vehicle

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Page 27: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Integrated ModelingCAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Mesh the geometry of Mesh the geometry of your caryour car

Page 28: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Integrated ModelingCAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Find the solar radiation Find the solar radiation in your cityin your city

Page 29: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Find the heat coming Find the heat coming into your carIntegrated Modeling into your car

CAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Page 30: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Model temperatures Model temperatures and airflow in the cabinIntegrated Modeling and airflow in the cabin

CAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Page 31: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Integrated Modeling

QQcondcond

TTambamb

QQevapevap

QQsolarsolar

TTairairTTmassmass

WWcompcomp

CAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

FrontFront--EndEndAir FlowAir Flow

Accumulator /Accumulator /DryerDryer

ElectricElectric--DrivenDrivenCompressorCompressor

CondenserCondenser

Expansion DeviceExpansion Device(Orifice Tube)(Orifice Tube)

EvaporatorEvaporator

Evaporator Air FlowEvaporator Air Flow(Outside Air or (Outside Air or RecircRecirc.).)

MOTORMOTOR

AlternatorAlternatorGeneratorGenerator

Find the power consumption and Find the power consumption and cooling amount of the ACcooling amount of the AC

Page 32: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Integrated ModelingCAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Model your car over a drive Model your car over a drive cycle and find the fuel cycle and find the fuel

economyeconomy

Page 33: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

How comfortable are How comfortable are you inside your car?Integrated Modeling you inside your car?

CAD

ThermalComfortVehicle

GlazingSolarRadiation

Cabin Thermal/Fluid

AirConditioning

FuelEconomy

TailpipeEmissions

OccupantThermal Comfort

Page 34: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Modeled Air Temperature ReductionBaseline• Gold exterior

• All Glazing - Sungate™• 25 scfm ventilation• White exterior

-7.9°C

Page 35: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

ADVISOR Model Summary

Reducing the A/C system 32% can: – Improve fuel economy 6% or 1 mpg (SCO3)– Reduce emissions of NOx by 12.8% or 0.05 gr/mi

Page 36: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 37: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Jeep Grand CherokeeParked Car Ventilation Test Program

Assess effect of:– Forced ventilation – Natural convection ventilation

DAIMLERCHRYSLER

Page 38: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Measured Cabin Air Temperature

30

32

34

36

38

40

42

44

46

Low flow / Panel Medium flow /Panel

Sunroof open6cm

Sidelites open2cm

Sunroof6cm/doublefloorvents

Sunroof6cm/double

floorvents/3 fans

Ventilation Technique

Cab

in A

ir Te

mpe

ratu

re (C

)

Ambient Temperature = 30C

Baseline Cabin Air Temperature = 45C

1.9C 13%

6.9C46%

2.0C13% 3.5C

23% 5.7C38%

7.5C50%

4.1 watts81 watts13 watts

Page 39: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 40: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

DaimlerChrysler Test Cells Correlation: Outdoor vs. Indoor

Outdoor TestsEmissions Test CellSodium Scandium dosed Metal Halide

Environmental Test CellIR –Tungsten Filament

Quartz Tubes

DaimlerChrysler, DCTC, Auburn Hills, MI

NREL, Golden, CO How well do indoor tests simulate

outdoors?

Page 41: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Indoor Temperatures Compared to Outdoor

9/15/02 Environmental Conditions

30

35

40

45

50

55

60

65

70

75

80

Windshield IP Driver Seat Air, average Trim, average Vehicle Exterior

Tem

pera

ture

(C)

OutdoorMetal HalideIR

-3.4

+0.5

-4.8

-13.8

-1.4 -2.3

+1.5 +0.7 -0.1 -0.4

+20.1

+24.5

(Averaged between 1:30 and 2:00 p.m.)

Page 42: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 43: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

JCI Distributed HVAC Project

Seat Body Coolers

IP Body Coolers

IP Recirc Inlet

Seat Recirc InletSeat Vent

• Assess human thermal comfort impact of JCI distributed HVAC system– Flow circulation & impingement– Steady state air temperature– Cooldown performance

Page 44: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Pathlines from Body Coolers and Seat Vents

Page 45: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Driver OverallEquivalent Homogeneous Temperature (EHT)

25

30

35

40

45

0 5 10 15 20 25

Time from Start of Cooldown (min)

Driv

er A

vera

ge E

HT

(°C

)

Baseline

Distributed HVAC

EHT – eqv. uniform temp. and 0 air velocity with same dry heat transfer as nonuniformtest conditions

Page 46: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 47: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Thermal Comfort Assessment ToolsPredicting the comfort of vehicle occupants

Human Thermal Physiological

Model

Human Thermal Comfort Empirical

Model

ADvanced Automotive

Manikin

Manikin presentation PsychologicalPhysiological

Page 48: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

ADvanced Automotive Manikin (ADAM)• On-board power, water, communications • Designed to respond to a transient, non-

uniform thermal environment like a human:• Sweating• Breathing

• Wears clothes• 175 cm tall, 61 kg• 126 elements (~120 cm2), 120 zones

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Surface Segment DetailsOuter surface - low porosity metal

Distribution layer -high porosity metal

Water barrier layer

Fine grid distributed heater wire

Carbon fiber structural backing and insulation

Multiple temperature sensor array

Backside heat flux gauge

Local controller and fluid control valve

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Segment with Exaggerated Sweat Rate

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ADAM’s Carbon Fiber Skeletal System

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Battery System

• 4 nickel-metal hydride modules

• Onboard charging • 2 hr capability

Modules in each thigh2 Modules in torso

ChargeController

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Breathing System• 5 L/min periodic exhalation

and inhalation• 10 L/min continuous

exhalation• 100% R.H. at body

temperature

Valve

Humidifier chamber Breathing controller

Page 54: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Breathing System (cont.)

Tubes to nose

Nose breathing port

Neck auxiliary breathing port (inlet for continuous exhale mode)

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IR Image of breathing

Heated plume of air

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Fluid System Filter

• Added to mitigate contamination problem with segment capillary tubes

Fluid reservoirFilter

Fluid pump

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ADAM’s Active/Inactive Segments

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Ready for a Brain!

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Human Thermal Physiological ModelA Numerical Person

• Predicts transient thermal response of the body

• Receives data from and provides data to ADAM

• ANSYS model (40,000 elements, transient, 3D)

• Fully parametric for size and position of the human

• Body mass (tissues, bones, organs)

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Human Thermal Physiological ModelThermoregulatory System

• Circulatory system (network of circular tubes of variable cross sections for arteries & veins)

• Respiratory system (series of tubes between the mouth and lungs)

• Published control equations used for heat generation, sweat rate, shivering rate, vaso-dilation/constriction

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Mesh

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Section View of Upper Right Leg

Skin

Fat

Muscle

Bone

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Circulation Network

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FEA Model of the Flow Network of Upper Arm

• Thermal-flow elements:– Conduction within fluid – Mass transport of fluid – Convective heat transfer

coefficient to tissues varieswith fluid flow rate

• Cross-section of elements adjustable at every time step for vaso-dilation/constriction

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Blood Vessel Temperatures

Hand Skin Temperatures

• Blood flow rate to arteries of 1380 cc/h @ 37ºC

• Muscle tissue 750 W/m3• Skin tissue 1005 W/m3

• Skin heat loss 100 W/m2

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Body Skin Temperatures

Body Section Temperatures

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Interface program

Substitute Table (model uses data from good segment in

place of a malfunctioning segment)

Heat flux multiplier(ability to adjust heat flux from ADAM)

Page 68: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

The Human Thermal Comfort Empirical Model

How You Feel Thermally

• Determines local thermal sensation

• Determines local and global thermal comfort (thermal perception) from local sensations

• Accounts for non-uniform and transient thermal environment of vehicle cabin

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Model Overview

PhysiologyTskin,local , Tskin,mean , Tcore

PhysiologyTskin,local , Tskin,mean , Tcore

Local Thermal Sensation: Sl

Local Thermal Sensation: Sl

Overall Thermal Sensation: So

Overall Thermal Sensation: So

Local Thermal Comfort: Cl

Local Thermal Comfort: Cl

Overall Thermal Comfort: Co

Overall Thermal Comfort: Co

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Human Subject Testing

• Individual segments (plus breathing temperature) were heated and cooled

• 110 separate tests performed at U.C. Berkeley

• 64 tests performed in Delphi wind tunnel

Test Condition

0

10

20

30

40

0 50 100 150 200

Time (min)

Air

Tem

pera

ture

(°C

)

Test Condition

0

10

20

30

40

0 50 100 150 200

Time (min)

Air

Tem

pera

ture

(°C

)

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Left Hand Cooling

0

5

10

15

20

25

30

35

40

15:36 15:43 15:50 15:57 16:04 16:12 16:19 16:26 16:33

Tem

pera

ture

(°C

)

-4

-3

-2

-1

0

1

2

3

4

Finger Temperature overall_sensation left_hand_sensation

Hand Cooling

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Back Cooling

0

5

10

15

20

25

30

35

40

14:52 15:00 15:07 15:14 15:21 15:28 15:36

Skin

Tem

pera

ture

(°C

)

-4

-3

-2

-1

0

1

2

3

4

Back Temperature overall_sensation back_sensation

Back coolingTroom = 28.2°C

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Body Core Heating With Local Cooling

37

37.1

37.2

37.3

37.4

37.5

37.6

13:

Tem

pera

ture

(°C

)

14:52 15:21 15:50 16:19 16:48

Pelvis CoolingLeft Hand CoolingHead Cooling

7:45

Troom=28ºC, Tsupply=12ºC

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Physiological/Psychological Model Coupling

PhysiologyTskin Tcore

PhysiologyTskin Tcore

Local Thermal Sensation

Local Thermal Sensation

Overall Thermal

Sensation

Overall Thermal

Sensation

Local Thermal Comfort

Local Thermal Comfort

Overall Thermal Comfort

Overall Thermal Comfort

Converts temperatures to sensation and

comfort

Page 75: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Linking the Tools Together

Dynamic interaction with

environment

120 surface heat fluxes transmitted

Transmits 120 target skin temperatures and

sweat rates

Surface and core temperatures transmitted

Is the environment comfortable?

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Model and Manikin Data Loop

FEA Output File of Ts

Model calculatesnew Ts setpoints and

writes to file ~2 minutesModel reads qlossevery ~2 minutes

Writes qloss to fileevery 15 seconds

Manikin Output File

of qloss

Manikin reads Ts setpoints,changes heater power, sweat

rate, and breathing

Manikin continuously adjusts heater power to meet Ts setpoints

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Manikin Controlled by Model

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Human & Manikin Comparison*>35.9°C

*<29.4°C

29.5

30.0

30.5

31.0

31.5

32.0

32.5

33.0

33.5

34.0

34.5

35.0

35.5

*>35.9°C

*<29.4°C

29.5

30.0

30.5

31.0

31.5

32.0

32.5

33.0

33.5

34.0

34.5

35.0

35.5

Page 79: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 80: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

VCCL Objective

Evaluate occupant thermal comfort response to advanced cabin climate control systems in a controlled asymmetric, thermal environment and predict impact on:

• Fuel use• Thermal comfort

Page 81: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Cabin Thermal Test CellSolar Simulator

Air Conditioning System Passenger Compartment

Room Temp. Control(hidden)

Page 82: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Solar Simulator Uniformity Test

Page 83: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Air Conditioning• Actual Neon A/C

System• Electrically Driven

– 5.6 kW motor (7.5 hp)

Motor Starter& Power Switching

Condenser & FanMotor

Expansion Valve

DesiccantFilter

Compressor

Page 84: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Thermal Comfort Test ProcessHeat Soaked Vehicle

Cool-Down Test

TC & VehicleModeling

Improved ComfortEnergy &

Fuel Saving

Page 85: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 86: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Objectives and Goals

• Our primary objective would be to utilize high-grade heat from engines in light-duty vehicles to produce cooling and/or electrical power generation.

• Our primary goal would be to reduce the fuel used by light-duty vehicles’ ancillary systems by 75% by 2010.

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Availability of Waste Heat in a Light-Duty Vehicle

1000 1500 2000 2500 3000 3500 4000 45000

50

100

150

200

2030 40

50

60

70

80

90

100

125

15

175

200

300

400500

Engine S peed (rpm)

Eng

ine

Torq

ue (N

m)

Engine Waste P ower (kW), Max P ower 115 kW Based on 1991 Dodge Caravan 3.0-L (102 kW) S I Engine - trans ient da ta

• Average waste heat available would be 23 kW.

• Exhaust temperature varied from 200oC to 600oC.

• Generally, the waste heat available is twice as much as the mechanical output of the engine

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Heat Generated Cooling Opportunities

Thermoacoustic EngineAbsorption Heat Pump Cycle

Zeolite/Desiccant Cooling Metal Hydride Heat Pump

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Heat Generated Electric Generation

Evaporator

Preheater

Thermoelectrics, Thermionics, and Quantum Well Technologies Organic Rankine Cycle

Thermoacoutic Resonator

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Waste Heat Utilization Laboratory

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Long Term: Waste Heat Utilization

• Too long-term for industry

• Potentially eliminate all fuel used for air-conditioning

• Opportunities exist but require R&D

No More Fuel Used for AC!

Page 92: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Outline• Introduction• Why A/C Systems?• Industry Collaborative Vehicle Projects

– Ford Lincoln Navigator Project• Solar Load Reduction• Parked Car Ventilation

– DaimlerChrysler• Integrated Modeling Validation• Parked Car Ventilation• Test Cell Comparison with Outdoor Testing

– Johnson Controls Distributed Cooling• Future Opportunities

– A.D.A.M.– Climate Control Lab– Waste Heat Utilization

• Conclusions

Millions of Gallons Used

for AC per Year

0120241361481601722842962

6

34

67

33

8

21249

883

219

18

144

16254

39

123

203

304

79

64

191

20

43

11

238

18

104

166

86154

13

136

82

218

9686155257

26

73

98

275

962

20

63

87498

291102

205

0

Page 93: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Solutions to Reduce AC Fuel UseVehicle Design

• Reduce the load (e.g. cabin soak temperature)

• Improve distribution of cooling• Improve equipment efficiency• Effective tools (modeling and testing)

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Future Opportunities• Implement integrated model with industry-

partnered vehicle testing to evaluate benefit of advanced climate control systems

• Evaluate advanced concepts with thermal manikin and modeling

• Demonstrate heat-generated cooling concepts

• Demonstrate heat-generated electricity concepts

Page 95: Ancillary Load Reduction Task Overview - NREL · PDF file– Ford Lincoln Navigator Project • Solar Load Reduction ... Technology Compressor Power Fuel Economy Improvement ... solar

Vehicle Level Opportunities• Reduced Fuel Consumption • Reduced Tailpipe Emissions• Increased Comfort• Avoided Costs - avoid second evaporator, tubes,

controls, ducts or larger system• Underhood Issues

– Space– Lack of air flow for cooling– Overheating components, particularly

battery and electronics– Condenser fan power

• Material life, color, and cost• Enable advance vehicle technologies

– HEV– FCV

Reduce compressor size and use

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Acknowledgments• Roland Gravel, U.S. Department of

Energy, Office of FreedomCAR and Vehicle Technologies (OFCVT)

• Barbara Goodman, Director, NREL Center for Transportation Technologies and Systems

• Terry Penney, NREL OFCVT Technology Manager

• Charlie King, NREL Technician

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Thank you

John Rugh303-275-4413

[email protected]://www.ott.doe.gov/coolcar

The U.S. Department of Energy’s

National Renewable Energy Laboratory