Browse Topic: Refrigerants

Items (443)
The purpose of this document is to establish guidelines for determining the critical R134a and R1234yf refrigerant charge for off-road, self-propelled work machines as defined in SAE J1116 and agricultural tractors as defined in ANSI/ASAE S390. It will develop a minimum to maximum refrigerant charge range in which the HVAC system can maintain proper operation. Operating conditions and characteristics of the equipment will influence the optimum charge. Since these conditions and characteristics vary greatly from one application to another, careful consideration should be taken to determine the optimum R134a and R1234yf refrigerant charge for the HVAC system.
HFTC6, Operator Accommodation
The anticipated PFAS ban in the US by 2029 has created a need to evaluate alternative refrigerant solutions for automotive thermal management systems. This work compares three candidates—Propane (R290), Carbon Dioxide (R744), and R1234yf—through system-level testing and demonstration projects. R1234yf remains the current industry baseline. Test results show that Propane (R290) delivers comparable efficiency while offering a significantly lower global warming potential. However, its flammability presents integration challenges, not present with R1234yf or R744. CO₂ (R744) demonstrated promising performance as well. To address safety concerns with Propane, AVL developed mitigation measures including rapid leak detection, robust containment strategies, and optimized circuit layouts designed to reduce ignition risks. These countermeasures were validated in practice through the European Commission’s QUIET project. Within this program, a Honda B-segment electric vehicle was equipped with a Propane-based heat pump, thermal storage, infrared cabin heating, and lightweight materials. Testing under real-world conditions showed a 25% increase in driving range in cold conditions while maintaining passenger comfort [25,25]. An AI-based control strategy further improved system efficiency by coordinating thermal and energy management. The findings demonstrate that Propane can be a feasible replacement refrigerant for electric vehicle applications if appropriate safety measures are implemented. CO₂ also remains a strong candidate, offering a cost-effective and PFAS-compliant solution. Together, these results contribute to the evaluation of sustainable refrigerants and provide guidance for future thermal system development in the automotive sector.
bires, MichaelPossegger, Jonathan
Automotive air conditioning systems are essential for ensuring thermal comfort for passengers. However, these systems require the elimination of refrigerants with high Global Warming Potential (GWP) and a transition toward more environmentally friendly alternatives. For many years, R134a has been the industry standard in automotive applications, following the phase-out of chlorofluorocarbons (CFCs) such as R12. This study evaluates the energy efficiency and environmental impact of several refrigerants in automotive air conditioning systems in tropical climates. A comprehensive literature review is conducted to select the refrigerants to be compared with R134a. The following is chosen: R1234yf, R744 (CO2), R290, R600a and R152a. Then a mathematical model is prepared and validated. The deviation between the results presented by the mathematical model and those in the literature varies from -1.21% to 8.33%. The simulation results suggest that the Coefficient of Performance (COP) of R152a and R600a is approximately 3% higher than that of R134a. However, these fluids are flammable, requiring additional safety investments. While R1234yf shows a slight loss in efficiency, at almost 4% lower than R134a, it offers a degree of compatibility due to its similar overall properties. The performance of R290 is slightly worse, while that of R744 is significantly lower. Finally, the environmental analysis based on TEWI indicates that R152a and R600a result in a slightly lower impact compared to R134a. In contrast, R290 and R1234yf exhibit a slightly higher environmental impact than R134a.
Oliveira Dias, Vinícius José deBarbieri, Paulo Eduardo LopesMoreira, Thiago Augusto AraújoSantos, Alex HenriqueFreitas Paulino, Tiago de
In early of 2023 the European Union began the process of banning the so-called Per- and polyfluoroalkyl substances, with a total elimination forecast for 2035. Currently, the refrigerant gas used by automakers is the R1234yf, a substitute for the R134a as a refrigerant with zero degree of ozone layer destruction, developed to meet the European directive 2006/40/EC that came into force in 2011. It requires all new car platforms for sale on the continent to use a refrigerant in their air-conditioning system with a Global Warming Potential below 150. The alternatives studies for the replacement of R1234yf are R744 (CO2) and R290 (Propane). The first is characterized by being a non-flammable gas and has a working pressure of 6 to 12 times higher than the current one. The second has the characteristic of having working pressure similar to R1234yf, but it is a highly flammable gas. This work focuses on the analysis of the two alternative gases to R1234yf, exploring their characteristics, detailing their impact on the systems, and discussing the challenges for the implementation of each of them.
Ariza, Valquíria RezendeErberelli, Diego PivattoSilva, Pedro Henrique Moraes daMiyauchi, Edison Tsutomu
This SAE Standard applies to equipment to be used with R-1234yf refrigerant only. It establishes requirements for equipment used to recharge R-1234yf to an accuracy level that meets Section 9 of this document and purity levels defined in SAE J2099. Refrigerant service equipment is required to ensure adequate refrigerant recovery to reduce emissions and provide for accurate recharging of mobile air-conditioning systems. Equipment shall be certified to meet all performance requirements outlined in this document and international/regional construction and safety requirements as outlined in this document.
ICTMS Service Committee
With the rapid adoption of new energy vehicles (NEVs), effective thermal management has become a crucial factor for enhancing performance, safety, and efficiency. This study investigates the steady-state and dynamic characteristics of a secondary loop CO₂ (R744) thermal management system designed for electric vehicles. The secondary loop system presents several benefits, such as improved safety through reduced refrigerant leakage and enhanced integration capabilities with existing vehicle subsystems. However, these advantages often come at the cost of decreased thermodynamic efficiency compared to direct systems. Experimental evaluations were conducted to understand the effects of varying coolant flow rates, discharge pressure, and dynamic startup behaviors. Results indicate that while the indirect system generally shows a lower coefficient of performance (COP) than direct systems, optimization of key parameters like coolant flow rate and discharge pressure can significantly enhance performance. Specifically, optimizing the coolant flow rate resulted in a COP increase of up to 92.6% under certain conditions, while proper management of discharge pressure improved the heating capacity and system efficiency. Additionally, dynamic analysis of startup behaviors revealed the importance of effectively managing refrigerant distribution to achieve stable system operation and minimize energy losses. These findings provide valuable insights into the engineering feasibility and potential improvements of secondary loop systems. By focusing on the optimization of flow rate, pressure management, and startup control, this study supports the development of more sustainable and energy-efficient solutions for the thermal management of NEVs, ultimately contributing to the wider adoption of environmentally friendly transportation technologies.
Zong, ShuoHe, YifanGuan, YanDong, QiqiYin, XiangCao, Feng
With the popularity of electric vehicles, the application development of heat pump type automobile air conditioning system has been focused. Meanwhile, the traditional R134a needs to be replaced by more environmentally-friendly refrigerants under the Kigali Amendment. In this paper, a novel direct expansion heat pump air conditioning system with three circuit switching (DXACS) was proposed, and three low GWP refrigerants R1234yf, R1234ze(E) and R290 were carried out to evaluate the system performance. The results show that the winter range attenuation ratio of DXACS is 26.9%, significantly lower than the prototype EV360 (57.5%); the DXACS with R290 shows the best heating performance, COPh and qcv are 2.3% and 57.3% higher than R134a in extremely cold conditions, respectively. This study provides valuable insights for the development of efficient and green thermal management technology of new energy vehicles.
Zhu, TengfeiLiu, YeChen, Qinghua
Energy saving and emission reduction is an important part of the development of electric vehicle technology. Thermal management system affects vehicle energy consumption and carbon emissions, and it is necessary to develop the next generation of thermal management systems to replace R134a with high-performance and low GWP refrigerant. In this paper, a dual-side indirect heat pump system architecture was designed to be compatible with R290 and R134a refrigerants. According to the results of the system bench test, the cooling and heating performance of the R290 system was better than that of the R134a system, and the charge amount of R290 was no more than 150g, which was safe for vehicle application. Therefore, the R290 dual-side indirect heat pump system can be used as a feasible solution for the next-generation thermal management system.
Wang, ZhimingYin, XiangCao, Feng
This SAE Standard provides testing and functional requirements to meet specified minimum performance criteria for electronic probe-type leak detectors. The equipment specified here will identify smaller refrigerant leaks when servicing motor vehicle air conditioning systems, including those engineered with improved sealing and smaller refrigerant charges to address environmental concerns and increase system efficiency. This document does not address any safety issues concerning the equipment design or use beyond that of sampling a flammable refrigerant, save those described in 3.1 and 3.2 of this document. All requirements of this standard shall be verified in SAE J2911.
ICTMS Service Committee
This SAE Standard applies to dyes intended to be introduced into a mobile air-conditioning system refrigerant circuit for the purpose of allowing the application of ultraviolet leak detection. In order to label any product(s), they shall meet SAE J2297, the certification process as described in SAE J2911 must be followed, and the documentation described in Appendix A shall be submitted to SAE.
ICTMS Fluids Committee
R-1234yf is used in almost every new car sold in the U.S., but the EU is discussing a ban and the industry is investigating alternatives like CO2 and propane. According to its manufacturer, Chemours, use of R-1234yf has grown so much since the refrigerant replaced the long-established R-134a that it's now used in 95% of new cars sold in the U.S. An estimated 220 million cars on global roads are also using it. The problem with R-134a, which came in cars and trucks in the 1990s, is that it's a gas with “a global warming potential (GWP) that is 1,430 times that of CO2,” according to the EPA. Since 2017, EU legislation has banned the use of any refrigerant in new vehicles with a GWP higher than 150. That rule doomed R-134a but opened the door for R-1234yf, which has a GWP of only four. The EU is currently revisiting R-1234yf emissions rules and may ban the substance in a few years. In the U.S., the EPA stands by its use.
Motavalli, Jim
SAE J3291 covers hoses and coupled hose assemblies intended for containing and circulating lubricant, liquid, and gaseous refrigerant in automotive air-conditioning systems. This recommended practice will be used to establish requirements for the validation of hoses, hose assemblies, or nonmetallic line assemblies with any new refrigerant or refrigerant blend being considered for use in automotive air-conditioning systems. The new refrigerants and blends covered by this document do not include current refrigerants R134a, R1234yf, and R152a. This document does not cover previously used refrigerant R12 nor refrigerants used in transcritical systems, such as R744. It is the system manufacturer’s responsibility to ensure that adequate compatibility testing is completed with new refrigerants, blends, and lubricant combinations together with intended hose materials. The recommended tests include, but are not limited to, volume swell, delamination, and rapid decompression. These tests are not included in the scope of this recommended practice. Data gathered while testing to this recommended practice shall be acceptable as applied to the final standard when released, providing that no substantive changes to the test methods or acceptance criteria have been made in the final standard. Details for certification per SAE J2911 will be included in a future revision.
ICTMS Supplier Committee
In electrified vehicles, auxiliary units can be a dominant source of noise, one of which is the refrigerant scroll compressor. Compared to vehicles with combustion engines, e-vehicles require larger refrigerant compressors, as in addition to the interior, the battery and the electric motors must be cooled. The compressor causes the acoustic excitation of other refrigeration circuit components and the chassis via pressure pulsations and vibration transmission, as well as emitting airborne sound directly. Sound measurements have been performed in an anechoic chamber to investigate the influence of operating conditions on the acoustics of an electric scroll compressor. This paper investigates the influence of the operating conditions on compressor acoustics and shows that rotation speed is the main factor influencing compressor noise. The sound spectra of fluid, structure and airborne noise are dominated by speed-dependent, tonal components. Additionally the effect of varying pressure, superheat, vapor content and refrigerant filling quantity on the acoustic properties of the scroll compressor have been investigated. The findings provide insights into the physical relationship between operating conditions and acoustic parameters and enable the development of suitable sound reduction measures.
Saur, LukasBecker, Stefan
Within this work a compact automotive heat pump module prototype with the natural refrigerant R290 (propane) is presented. R290 is non-toxic, has a low global warming potential (GWP) of 3, is environmentally friendly and is not affected by PFAS restrictions. Furthermore, R290 has a superior efficiency compared to refrigerants like R1234yf & R134a, which makes it a promising alternative. A test setup is built to evaluate the performance of the prototype HP-module, which is charged with approx. 190g of refrigerant and reaches a cooling/heating capacity of approx. 11kW/16kW at the investigated conditions. In addition, a 1-D numerical tool for the calculation of steady state conditions is implemented in MATLAB/Simscape and validated by time-averaged test data. The objective of the numerical tool is to be able to quickly predict the pressure levels within the refrigerant loop in advance to testing, as the pressure levels of the HP-module are not directly controlled, but result from the operating conditions (i.e., eCC speed, eXV position, coolant loop volume flow rates and inlet temperatures).
Pogorelov, AlexejReimers, Thorsten
A ban on Per- and Polyfluorinated Substances (PFAS) has enforced automobile companies to find alternatives to current R1234yf refrigerant. One such natural substitute, R290 (propane), is becoming popular with automotive manufacturers and suppliers due to its high performance and efficiency. However, due to its high flammability, R290 is not allowed in the cabin evaporator/condenser in order to ensure the safety of the driver and passenger. This requires the design of a novel indirect Heat Flux Management System (HFMS) with coolant as a working fluid to transfer heating to cabin and powertrain cooling components. The design of the heat pump system confines flammable R290 refrigerant to a hermitic compact box to avoid leakages. This paper aims to investigate the performance and efficiency of a new R290 refrigerant-based indirect heat pump system. The system is tested on a test bench, and the results are compared to an indirect heat pump system with R1234yf refrigerant. The study and results are used to check the feasibility of introducing R290 refrigerant as a potential alternative to PFAS refrigerant in automotive systems and related domains.
Gupta, RaghavSaraswat, RohanGravelle, Aled
In developing nations, most passenger vehicles are equipped with mobile air conditioning (MAC) systems that work on Hydro Fluoro Carbons (HFC) based refrigerants. These refrigerants have a high global warming potential (GWP) and hence adversely affect the environment. According to the Kigali amendment to Montreal Protocol, Article-5 Group-2 countries including India must start phasing down HFCs from 2028 and replace them with low Global Warming Potential (GWP) refrigerants. One such class of low GWP refrigerant is Hydro Fluoro Olefins (HFO) In order to replace HFCs with HFOs in existing MAC systems, the various system performance parameters with the new refrigerant are required to be evaluated. Performance evaluation of MAC system is rendered quicker and cost-effective by deploying a digital simulation tool. There is good correlation and confidence established for MAC performance prediction with HFCs through 1D CAE. Further, to enable AC performance simulation with drop-in refrigerant through 1D CAE, a simulation methodology needs to be formulated to build correlation with physical test. This work comprises generating the physical test data by replacing the R-134a refrigerant in a test vehicle with low GWP R-1234yf drop-in refrigerant. The MAC system performance is validated at severe ambient condition (>40°C) and then compared with baseline performance with R-134a refrigerant. Preliminary work comprises performing first-cut simulation by replacing R-134a in the correlated model with R-1234yf and analyzing the gap between physical test data and 1D CAE outcome. A sensitivity analysis is carried out to understand the impact of different parameters like warm-up temperatures, duct heat gain values etc. on MAC performance. Simulation results obtained by tuning these parameters are found to correlate with physical test data by > 95% accuracy. With the correlated model, this simulation methodology is deployed for another vehicle to predict the MAC performance with drop-in refrigerant. The proposed methodology will help to understand the impact of drop-in refrigerants on present HFC-based MAC systems and enable us to provide feasible recommendations to meet the target MAC performance for intended climatic usage conditions well before prototyping and physical validation.
Kulkarni, ShridharShah, GeetJaybhay, SambhajiVarma, Mohit
Air-conditioning and Refrigeration systems are widely used in many industries for cooling and preservation, and the evaporator is a crucial component responsible for heat absorption. The choice of refrigerant has a significant impact on the evaporator's performance, affecting the overall efficiency of the system. This paper investigates the effect of three common refrigerants, R134a, R407c, and R1234yf, on evaporator performance. A comparative analysis was performed using the conventional air-conditioning system consisting of a compressor, condenser, expansion valve, and evaporator. The evaporator performance was evaluated based on the cooling capacity, Refrigerant Side Pressure Drop (RSPD) and Superheat (SH). The results show that evaporator has highest cooling capacity with R134a, followed by R407C and R1234yf. In comparison to R134a, R1234yf had the lowest refrigerating effect followed by R407C. However, R1234yf has the lowest Global Warming Potential (GWP) value out of all the three refrigerants. These results suggest that depending on the thermal conditions of the AC system, evaporator performance varies accordingly. However, R1234yf is more expensive and has a slightly lower cooling capacity than R407c & R134a at low evaporation temperatures, which should be considered before selecting a refrigerant for a specific application. In conclusion, the choice of refrigerant has a significant impact on the evaporator's performance in refrigeration systems. The findings of this study provide insight into the performance of three commonly used refrigerants and suggest that depending on the requirements and standard guidelines either of the three refrigerants i.e. R134a, R407C and R1234yf with higher thermal performance at a specified condition can be used. However, other factors such as cost and application requirements should also be considered when selecting a refrigerant.
Suman, SaurabhKushwah, Yogendra Singh
Today, most vehicles in developing countries are equipped with air conditioning systems that work with Hydro-Fluoro-Carbons (HFC) based refrigerants. These refrigerants are potential greenhouse gases with a high global warming potential (GWP) that adversely impact the environment. Without the rapid phasedown of HFCs under the Kigali Amendment to the Montreal Protocol and other actions, Earth will soon pass climate tipping points that will be irreversible within human time dimensions. Up to half of national HFC use and emissions are for the manufacture and service of mobile air conditioning (MAC). Vehicle manufacturers supplying markets in non-Article 5 Parties have transitioned from HFC-134a (ozone-safe, GWP = 1400; TFA emissions) to Hydro-Fluoro-Olefin, HFO-1234yf (ozone-safe, GWP < 1; TFA emissions) due to comparable thermodynamic properties. However, the transition towards the phasing down of HFCs across all sectors is just beginning for Article 5 markets. Patents on R-1234yf will soon expire, just as scarcity is likely to drive the price of R-134a to historic highs. This work consists of two case studies, specific to an Internal Combustion Engine (ICE) and an Electric Vehicle (EV). Two different refrigeration system architectures are examined. Both the shortlisted vehicles have different and complex AC system architectures. Complex AC system architectures are selected in this study with the objective of understanding and deploying the learnings in vehicles with less complex and simpler AC system architectures. The ICE vehicle selected for the study has a dual AC configuration with two cooling points (front and rear), using DX architecture. In the EV, an architecture similar to that of the ICE vehicle is deployed for cabin cooling, but unlike the ICE vehicle, it has a secondary coolant-based loop provisioned for battery thermal management. For this study, the baseline HFC-134a refrigerant is replaced by a ‘drop-in’ alternate low-GWP HFO-1234yf refrigerant in both vehicles. This study focuses on cooling performance evaluation with existing HFC refrigerant and proposed HFO refrigerant for both AC system architectures, gap identification, and proposing common and unique solutions for bridging the performance gaps.
Maurya, AnuragMehta, BhavikSardesai, SureshSwarnkar, SumitVenu, SantoshKapoor, Sangeet
Compressor plays an important role in Automotive Air Conditioning (AC) System. It compresses the low pressure refrigerant and discharges the high pressure refrigerant vapour to condenser. Compressor performance mainly depends on two parameters, compressor oil and refrigerant gas charge quantity. Compressor oil is used to lubricate the movable parts in reciprocating compressors. Compressor oil is miscible in refrigerants in liquid state and amount of oil present in compressor increases the life of compressor. But, huge amount of oil may also reduce the thermal performance of system. Minimum gas quantity gives poor cooling performance and due to maximum quantity, increasing suction/discharge pressures, results in more compressor work and low cooling. This paper discusses the experimental analysis of refrigerant quantity, oil quantity in different ratios to improving the cooling performance of a passenger vehicle. Experimentation was conducted on 7 seater passenger car (hatchback). For experimental study, testing was carried out inside Climatic Chamber under ambient conditions, road conditions. Grill level temperature were recorded over time to predict the passenger cabin cooling performance. Refrigerant side temperature, suction and discharge pressure were recorded at different charge quantity to understand the refrigerant side thermal performance. From the experimental study, Optimum refrigerant and oil quantity was determined.
Meena, Avadhesh KumarKishore, KamalAgarwal, RoopakParayil, Paulson
This SAE Standard applies to refrigerant identification equipment used for identifying an acceptable level of R-1234yf purity in a refrigerant tank or vehicle MAC system labeled as containing R-1234yf, and not misidentify other refrigerants, per 5.7.
ICTMS Service Committee
This SAE Standard provides the testing and functional requirements guidance necessary for a leak detection device that uses any non-A/C refrigerant tracer gas, such as helium or a nitrogen-hydrogen blend, to provide functional performance equivalent to a refrigerant electronic leak detector. It explains how a non-refrigerant leak detector’s calibration can be established to provide levels of detection equal to electronic leak detectors that meet SAE J2791 for R-134a and SAE J2913 for R-1234yf.
ICTMS Service Committee
The oil circulation rate (OCR) is a deciding factor for the performance of automotive air conditioning systems at both the system and component levels. OCR is defined as the percentage by mass of oil present in a representative sample of oil-refrigerant mixture drawn from the system at steady state. In recent years, many industries are opting for low-OCR compressors, and so the OCR values are getting smaller, making it even more important to be able to accurately measure the OCR in the system. All the different OCR measurement techniques rely on the ASHRAE Standard 41.4 for proper calibration. This standard describes OCR measurement using a sampling technique which involves connecting an evacuated sampling cylinder at the liquid line of the system at steady state to draw a sample containing the liquid mixture of refrigerant and oil. However, several factors such as orientation of sampling cylinder and valve opening speed can affect the OCR results. The flow entering the sampling cylinder initially consists of both liquid refrigerant and liquid oil. As the valve on the sampling cylinder is opened, the refrigerant undergoes flashing followed by recompression and re-condensation of vapor refrigerant, and simultaneous filling up with liquid mixture until pressure equalization between the system supply line and evacuated sampling cylinder is achieved. This two-phase, two-component, phase changing flow is complex, and for the present study, flow visualization using a high-speed camera and analytical tools are used to study the flashing flow of pure refrigerant entering an evacuated sampling cylinder. The obtained results are used to compare with those obtained with oil-refrigerant mixture to shed light on how parameters such as sampling cylinder orientation and valve opening speed can affect the measured OCR values.
Haider, Syed AngkanWang, XinElbel, Stefan
The heat pump with low global warming potential (GWP) refrigerants is imperative for the electric vehicle (EV) to slow down global warming and extend the driving range while meeting passengers' thermal comfort in low ambient temperatures. However, there are no appropriate refrigerants. To provide long-term and environmental-friendly refrigerants in the heat pump for EVs, herein, we reported newly developed low-GWP refrigerant mixtures, i.e., DL3B, whose GWP is lower than 140, the flammability (lower flammability limit and burning velocity), saturation pressure, lubricant miscibility, material compatibility were experimentally tested. A test bench that can investigate the performance of an R410A prototype was built. The drop-in tests of the DL refrigerant were carried out to evaluate the capacities and COPs for both cooling and heating modes in the EV heat pump system. Results showed that DL3B has similar saturation pressure to R410A, good miscibility with original lubricant and is compatible with both metallic and non-metallic materials. 6.The heating capacities of DL3B were 101.8-112.8% of the R410A system, with COP being 84-99.8%, while the cooling capacities showed 118.9-128.4% of the R410A system, with COP being 98.2-108%. DL3B showed very weak flammability and can be classified as A2L according to the ASHRAE standard. Besides, our real car road test showed very good heating performance even in -25 °C ambient temperature with similar warm-up performance to R410A. Our results certificated the promising potential application of the DL refrigerant in EV heat pumps.
Yu, BinbinQian, ChenyiOuyang, HongshengShi, Jun-YeGuo, ZhikaiChen, Jiangping
The compressor oil is retained at different locations of the vapor compression system during operation. After shutdown, retained oil absorbs the vapor refrigerant and mixes with the liquid refrigerant gradually. Oil retention can largely affect the heat transfer and cause insufficient oil return. In this paper, the liquid mixture behaviors at the compressor suction and discharge are observed by flow visualization. Liquid mixture property variations are estimated by existing models according to the temperature and pressure variations. At the suction, the vapor refrigerant solubility with oil rapidly increases due to the pressure increase. The viscosity and surface tension decrease quickly with temperature and refrigerant mass fraction increase in the liquid layer. Flow visualization shows that the mixture film breaks from the top of the tube wall and flows down. The oil-refrigerant mixture accumulates at the bottom of the tube within seconds. The liquid level increases then decreases. At the discharge, the refrigerant solubility fluctuates within a small range. Viscosity increases because of temperature decrease then decreases because of refrigerant mass fraction increase. After shutdown, the oil flow in contact with the inner wall of the discharge stops immediately while oil droplets in the vapor core flow slow down gradually. In the end, oil droplets flow down, coalesce with the oil film, and accumulate at the bottom of the tube. The vapor refrigerant, liquid refrigerant and oil relationship is investigated and estimated after shutdown to better understand oil retention.
Wang, XinHaider, Syed AngkanElbel, Stefan
The purpose of this SAE Standard is to define a common set of thermodynamic test conditions to evaluate internal heat exchangers for use with R-134a and R-1234yf refrigerants in mobile air-conditioning systems. This SAE Standard can be used to test actual vehicle IHX designs or standardized IHX samples, which can be used for comparison based on a common length and shape.
ICTMS Vehicle Manufacturer Committee
To provide a procedure to inspect a refrigerant cylinder used in equipment servicing mobile air-conditioning (A/C) systems. This includes the pressure cylinder used for refrigerant recovery/recycling and charging equipment.
ICTMS Fluids Committee
Air conditioning these days has become an indispensable part of human comfort due to rising global temperatures. In order to achieve thermal comfort in confined environments like residences, car passenger cabins, offices, etc., air conditioners are used. As the air conditioning units employ dynamic processes to maintain thermal comfort it creates many unwanted noises which lower the acoustic comfort. One of these unwanted noises is the refrigerant flow induced noise inside passenger cabin of an automobile when the air conditioning is switched on in a thermally soaked vehicle. This paper elaborates about the study conducted on a HVAC system mounted on a calorimetric bench in a semi-anechoic chamber to understand the noise signatures and acoustic characteristics of refrigerant induced noise. This research investigates potential causes and solutions for noise generated by refrigerant flow. Additionally, using a typical NVH study setup, it assesses several mitigation strategies that have been investigated to eliminate or reduce noise caused by refrigerant flow. This study also tries to categorize and evaluate the decline in sound quality caused by the noise that is continuously generated by refrigerant-flow inside a car's passenger compartment.
Sharma, RachitKumar, MukeshKumar, ShubhamPatra, Subhashree
This SAE Standard covers equipment used to remove contaminated R-134a and/or R-1234yf refrigerant from mobile air conditioning (MAC) systems.
ICTMS Service Committee
The scope of this SAE Information Report is an evaluation of the ports and tools used on automotive air-conditioning systems to evacuate and charge systems with approved refrigerants during vehicle service. A task force was formed in April 2021 to perform this evaluation and concluded its work in September 2021. The scope of the task force was to evaluate issues being reported from service repair shops with air-conditionings service ports and the tools being used to connect to these ports. The task force also evaluated published SAE J Standards and discovered many of these standards did not include the necessary requirements for service ports and tools. The task force published a final report of its findings and recommendations. The report includes recommendations to correct and publish new SAE Standards related to the scope of this project.
ICTMS Supplier Committee
As one of the key components of the heat pump system, the electronic expansion valve mainly plays the role of throttling and reducing pressure in the heat pump system. The refrigerant flowing through the orifice will produce complex phase change. It is of great significance to study the internal flow field by means of CFD calculations. Firstly, a three-dimensional fluid model is established and the mesh is divided. Secondly, the phase change model is selected, the material is defined and the boundary conditions are determined. According to the principle of the fluid passing through thin-walled small holes, the flow characteristics of electronic expansion valve are theoretically analyzed. Then the flow characteristics of expansion valve are numerically calculated, and a bench for testing mass flow rate of the expansion valve is built. Then the theoretical value, CFD value and experimental value are compared to verify the correctness of the established three-dimensional fluid model. The flow rate changes of expansion valve are studied under the condition of changing geometric parameters such as the cone angle of the valve spool and the radius of circular arc at the end of the valve seat. According to the momentum theorem, the steady hydraulic force is theoretically deduced. Then the changes of steady hydraulic force are studied under the conditions of different inlet pressure and outlet pressure. At the same time, there also analyzes the effects of the conditions of different valve spool cone angle and valve seat arc radius on steady hydraulic force on the valve spool. Finally, transient analysis is carried out by using dynamic mesh technology. The speed of spool movement is defined by User Defined Function (UDF). Under constant pressure difference conditions, the influence of the spool movement on the hydraulic force and outlet flow of the valve is studied. And the change of the internal pressure field are shown.
Liang, GaoshuaiLi, LipingShangguan, Wen-Bin
The purpose of this SAE Standard is to provide minimum performance and operating feature requirements for the recovery of HFC-134a (R-134a) refrigerant to be returned to a refrigerant reclamation facility that will process it to the appropriate AHRI 700 Standard or allow for on-site recycling of the recovered refrigerant to SAE J2788 specifications by using SAE J2788 or SAE J3030 -certified equipment. It is not acceptable that the refrigerant removed from a mobile air-conditioning (A/C) system with this equipment be directly returned to a mobile A/C system. An identifier certified to SAE J2912 is to be used to identify the contents of the system prior to recovery of the refrigerant.
ICTMS Service Committee
Mobile air conditioning (MAC) systems used in passenger cars and light duty trucks are covered by these SAE Standards when servicing the refrigerant system. Technician training is required to ensure that recommended procedures are used for service and repair of MAC systems using R-12, R-134a, R-1234yf, R-744, and R-152a refrigerants. Unique requirements for each refrigerant are detailed within this standard. Technicians may be trained in any or all refrigerants. The technician shall be trained to recognize which refrigerant is being handled and how to handle it safely, and be equipped with the essential information, proper equipment, and tools which are unique to these refrigerants. This standard outlines minimum content requirements for such training programs. Training programs designed in accordance with this standard are not intended to ensure or assess the technical skills of technicians regarding the diagnosis and repair of motor vehicle air conditioners. Rather, the goal of such programs is to provide information to technicians about safely handling refrigerants and control of emissions during service.
ICTMS Service Committee
The scope of this document is to aid in the selection of hose and hose assembly titles.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
In this present investigation an attempt has been made to simulate the refrigerant flow through pipes using Computational Fluid Dynamics (CFD) to observe liquid refrigerant R134a flashing phenomenon using multi-phase model in ANSYS Fluent. In a vehicle HVAC piping system the refrigerant flows under a certain operating condition and pipe packaging. When the vehicle is kept in idle condition there is a possibility that a local pressure drop may occur due to change in pipe configuration or change in operating conditions. This leads to phase change and it can be one of the factor which causes noise and vibrations in the refrigerant pipe. The unwanted noise created due to refrigerant fluid phase change inside HVAC pipe can be annoying to end user. Prediction of refrigerant flow noise through HVAC pipes is more challenging and a time consuming process. Also this is more important for OEM’s to predict source of noise at very early stage of vehicle development which is caused because of refrigerant phase change. In current paper, a detailed CFD simulation study has been done with a capillary tube as a start point for basic understanding of the phase change physics in refrigerant pipe. This developed competency will enable us to set a process to deploy this on an actual HVAC pipe. A two phase Eulerian multiphase flow is used as it is better suited to capture a thermal phase change phenomenon. Fluid properties have been assumed to vary as piecewise linear. A good correlation was obtained with available experimental data from Li-et-al on [1].
JOSHI, RAHUL ASHOKBiswas, KundanTare, Kedar
Mobile Vehicle Air Conditioning (MVAC) systems are a substantial source of greenhouse gas (GHG) emissions. The use of high-GWP R-134a in MVAC systems contributes a lot to the inflated climate footprint of the segment. In recent years, with the Kigali Amendment in 2016, there has been an increasing push from the regulators in the US and EU to make a shift from R-134a to more climate friendly refrigerants such as olefins (R-1234yf), low-GWP HFCs (R-152a) and carbon dioxide (CO2). In terms of development and demonstration, these alternative technologies have come a long way in the last few years and are almost ready to be implemented. However, barring a few instances, the uptake and deployment-at-scale of these technologies have not really taken place till now in India, and in other parts of the world despite the regulatory push. In this context, this paper will take stock of the challenges in deploying and implementing these technologies at scale, particularly with an eye to domestic realities in India, as well as the ideal policy landscape which can facilitate the mainstreaming of alternative refrigerant technologies.
Dixit, Himanshu
The scope of SAE J2064 covers coupled hose assemblies intended for containing and circulating lubricant, liquid, and gaseous R-134a, R-152a, and/or R-1234yf refrigerant in automotive air-conditioning systems. Historically, requirements for the hose used in coupled automotive refrigerant air conditioning assemblies was included in SAE J2064. SAE J2064 has been changed to establish the requirements for factory and field coupled hose assemblies. SAE J3062 has been issued to define requirements for the hose used in these assemblies into its own standard. SAE J2064 also provides the necessary values used in SAE J2727. The certified coupling of MAC hose assemblies is required in meeting certain regulatory requirements. A hose which has met the requirements of SAE J3062 and certified in SAE J2911 shall be used as part of the coupled assembly. A hose which meets the requirements of SAE J3062 does not ensure the assembly will meet the requirements of SAE J2064. It is the hose assembly manufacturer’s responsibility to confirm that the assemblies meet the specified acceptance criteria for this specification. The hose assembly shall be designed to minimize permeation of the refrigerant, contamination of the system, and to be functional over a temperature range of -30 to 125 °C. Specific construction details are to be agreed upon between user and supplier. Bulk hose produced prior to the release of this standard in 2015 could be labeled “SAE J2064” and may not meet the requirements of SAE J3062.
ICTMS Supplier Committee
The “system emissions chart” contained herein is intended to serve as a means of estimating the annual refrigerant emission rate (grams per year) from new production A/C systems equipped with specified component technologies. It provides emission values for various component technologies that are currently available, and can be expanded as new technologies are commercialized. This document provides the information to develop an Excel file template “system emissions chart” for system emission analysis. The chart includes automotive compressor technologies for conventional mobile air conditioning systems, as well as those using semi-hermetic compressors. This standard can be considered a companion document to SAE J2763. SAE J2727 estimates system emissions, taking into account production assembly variation and accounts for components that are 100% helium leak tested prior to vehicle final assembly. The results from SAE J2064 are used to better represent permeation emissions from different hose material and coupling configurations in this version. SAE J2763 may be used to quantify emissions from properly assembled systems.
ICTMS Vehicle Manufacturer Committee
This SAE Standard applies to refrigerant vapor compression systems that provide cooling and/or heating for passenger cars, light trucks, and commercial vehicles (on and off road) that use automotive type mobile air conditioning (MAC) systems. Large trucks, buses, and other vehicles that do not use typical automotive A/C systems or use refrigerants not listed in this document are not covered by this standard. This standard covers vehicles with MAC systems using belt driven compressors and electric motor driven compressors. This document provides industry-recognized standards for the design, assembly, and test of MAC systems, including necessary service equipment, and is intended to cover all phases of the lifetime of MAC systems to minimize environmental, health, and safety impacts. The standards listed in this document cover the currently accepted industry guidelines and procedures. The standards can be used as requirements for regulatory authorities to meet minimum environmental, health, and safety requirements. Also included are cautionary statements for the service industry to alert technicians to the inadvisability and possible health or safety effects associated with venting refrigerant during service. It is not intended to restrict the use, or further development of, other types of refrigerants or refrigeration systems for MAC applications. This document may be amended, or additional safety standards created, should other refrigerants or refrigeration systems become practical. This document addresses only HFC-134a (R-134a), carbon dioxide (R-744), HFO-1234yf (R-1234yf), and HFC-152a (R-152a) refrigerants. For R-152a refrigerants, this standard will only apply to secondary loop systems. To prevent system contamination, all refrigerants used in MAC vapor compression systems require unique service fittings and service equipment. The unique service fittings are intended to significantly reduce the potential for refrigerant cross-contamination during service activities. CFC-12 (R-12) is no longer in use in new MAC systems. The service fitting description is maintained as a reference for older vehicles still in use. When retrofitting an R-12 system to use R-134a or when removing R-12 (during vehicle disposal), use service equipment designed for R-12 and certified to meet the requirements of SAE J1990 (R-12 recovery and recycle equipment).
ICTMS Vehicle Manufacturer Committee
The automotive application places very special demands on the air conditioning system. As is the case with any other process, system efficiency is very important and the automotive air-conditioning application is no exception. While the characteristics of all the major components in the air conditioning system like compressor, condenser, evaporator and blower contribute to overall system efficiency, localized inefficiencies do play a part and so must be kept to a minimum, especially in this day and age when extra emphasis is being laid on sustainability. One such phenomenon that contributes to the system inefficiency is heat pick-up in suction line. Since the temperature at the evaporator-outlet is quite lower than ambient and also its surroundings (steering system pipes and hoses, engine, air intake pipes and so on), the refrigerant picks up heat as it moves along the suction line up to the compressor inlet. This heat pick-up is detrimental to the overall system performance. Even though most of the automotive HVAC engineers are fairly aware of the undesirable effects of heat pick-up in suction line, many a times the heat picked up in suction line is seen only in terms of °C rise in temperature from evaporator-outlet to compressor-inlet and thus we are not able to visualize or quantify the extent of its impact on other parameters. With the help of case studies, this paper aims at providing a methodology for determining and arriving at the conservative estimate of the impact of heat pick up in suction line on parameters like compressor-outlet temperature, refrigerant mass flow rate, work of compression, refrigeration effect and COP. The results thus obtained provide a greater understanding of the said undesirable effects of heat pick-up in suction line, so that necessary actions could be taken to address the same.
Dubey, Mayank ManojTadigadapa, SureshGhorpade, SantoshShukla, AnkitReddy, Y.S.Sarath
This SAE Standard describes methods to understand the risks associated with vehicle mobile air conditioning (MAC) systems in all aspects of a vehicle’s lifecycle including design, production, assembly, operation, and end of life. Information for input to the risk assessment is provided in the appendices of this document. This information should not be considered to be complete, but only a reference of some of the data needed for a complete analysis of the risk associated with the use of refrigerants in MAC systems.
ICTMS Vehicle Manufacturer Committee
With the passage of the Kigali Amendment to the Montreal Protocol, HFC-134a refrigerant will be phased down in all markets worldwide, including those where automotive companies have been slow to embrace HFO-1234yf. Engineers are currently being challenged to design MAC systems using alternate low GWP refrigerants that are allowed by regulations, and are simultaneously cost-effective to manufacture, energy efficient, safe, reliable, affordable for consumers, and also suitable in electrified vehicles. This paper documents the latest international research and developments on: 1) refrigerants that satisfy the Montreal Protocol and national environmental regulations; 2) secondary loop MAC (SL-MACs) that achieve lower refrigerant emissions and higher energy efficiency in cooling-only and cooling and heating (heat pump) applications; 3) progress in Europe, North America, and Asia on heat pump systems for electric and hybrid vehicles optimized for safety and energy efficiency, and 4) the latest SAE standards for the emerging use of HFC-152a in SL-MACs. The authors of this paper are an interdisciplinary team from organizations based in China, Germany, India, Italy, and the United States, including experts from vehicle manufacturing, AC component and system suppliers, and non-government environmental organizations.
Craig, TimothyAndersen, Stephen O.Chen, JiangpingChowdhury, SouravFerraris, WalterHu, JianxinKapoor, SangeetMalvicino, CarloandreaNagarhalli, Prasanna VSherman, NancyTaddonio, Kristen
The purpose of this SAE Standard is to define a common set of thermodynamic test conditions to evaluate internal heat exchangers for use with R-134a and R-1234yf refrigerants in mobile air-conditioning systems. This standard can be used to test actual vehicle IHX designs or standardized IHX samples, which can be used for comparison based on a common length and shape.
ICTMS Vehicle Manufacturer Committee
To document and provide access to information obtained by an industry survey.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
The purpose of this SAE Standard is to establish the specific minimum equipment performance requirements for recovery and recycling of HFC-134a that has been directly removed from, and is intended for reuse in, mobile air-conditioning (A/C) systems. It also is intended to establish requirements for equipment used to recharge HFC-134a to an accuracy level that meets Section 9 of this document and SAE J2099. The requirements apply to the following types of service equipment and their specific applications. a Recovery/recycling equipment b Recovery/recycling-refrigerant charging c Refrigerant recharging equipment only
ICTMS Service Committee
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