Automotive mobile air conditioning (MAC) systems rely on effective thermal insulation to maintain cabin comfort and energy efficiency. However, insulation materials degrade over time due to thermal cycling and environmental exposure, impacting overall system performance. This study investigates the effects of reducing insulation material density (GSM) in critical areas such as the engine firewall, plenum, roof and door panels on MAC system efficiency.
A multi-disciplinary approach combining basic engineering calculations, frontloading CAE simulations and targeted experimental testing was employed. Initial calculations provided directional input for cabin heat load analysis, guiding early-stage design decisions. Simulation models were used to predict the impact of insulation reduction on cooling performance, energy consumption and component durability, reducing reliance on iterative physical testing. Experimental validation was then conducted selectively, focusing on critical areas to assess heat transfer effects and their influence on superheat and sub-cooling control.
Results demonstrated a streamlined validation process that minimizes physical testing, accelerates development cycles and optimizes AC system performance while reducing costs. By integrating simulations with smart testing strategies, this methodology enhances efficiency, ensures component durability and supports the development of cost-effective and high-performance automotive thermal management solutions.