2a sessione

1. Air Conditioning technology scenario and impact of
current Regulations
Carloandrea Malvicino
EMEA Vehicle Safety and Regulation Compliance
CO2 Emissions Reduction Strategies
Member of UN EP RTOC (Refrigeration, Air Conditioning and Heat pumps Technical Options Committee)
MAC system chapter leading author
June 2017

2. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Summary
2
• Automotive Scenario
• Mobile Air conditioning refrigerants
• Thermal Systems evolution opportunities
Montreal Protocol
Signed on September 16th 1987
30th anniversary

3. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
• Road mobility and transports are globally asked to reduce of up to 30% the
GHG emissions in the next 5 years
• Global road mobility will remain based on thermal combustion engine while
electrification will diffuse progressively function of regional needs
• Product and Technologies have to be Global but adaptable to Regional
requirements
• The Product Cost will become even more relevant
• Thermal system can play a key role and there are opportunities
• to improve the vehicle efficiency integrating properly the thermal systems
• to enable new functions (e.g. pre-cooling, comfort while idling, …)
• to make the refrigerant a «non issue»
Take aways
3

4. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Worldwide CO2 Targets for passenger cars
4
Targets set by Regulations
base data from http://www.theicct.org/global-pv-standards-chart-library
The GHG emission reduction is worldwide driven binding regulations
a on top to MAC and F Gas regulations
b credits are granted for using low GWP refrigerants
a
a
b

5. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
World Fuel Scenario
5
The Outlook for Energy: A View to 2040 - EXXON Mobil 2015
Passenger Cars Sales
Forecast
Internal Combustion Engines will remain by far even more
largely adopted for heavy duty vehicles where the majority
will be based on advanced diesel engines
Gasoline will remains the most diffused
fuel type being the most adopted also for
hybrids.
Gasoline will remains the most diffused
fuel type being adopted also for hybrids.

6. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Very different scenarios…
6
…but a global market
making the automotive business quite challenging…
Approx. 1.5 Billion of
vehicles circulating
world wide
(http://www.oica.net/category/vehicles-in-use/)
Approx 1.0 Billion
MAC units

7. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Mobile Air
Conditioning and
Refrigerants
7

8. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
REFRIGERANTS
8
 In 2006, the European MAC directive was decided to promote the
adoption of low GWP refrigerants in Europe (GWP<150) (2011-2017)
 Low-GWP synthetic refrigerants were developed during 2006-2011
(and this is still ongoing), all of the HFO type mainly because of MAC
applications (HFO-1234yf)
 The future of MAC, in relation to HFO-1234yf, CO2, dual loop etc… is
still open also considering the costs for developing countries to
convert to HFO-1234yf and the uncertainty where it concerns the
application of HFC-HFO mixtures (containing HFO-1234ze)
 In the end there is need to have a limited amount of options
sourcer DEALING WITH HFCs UNDER THE MONTREAL PROTOCOL WHILE INTRODUCING LOW-GWP ALTERNATIVES - Lambert Kuijpers- A/genT Consultancy (UNEP TEAP
Senior Expert) - 12th IIR Gustav Lorentzen - Natural Working Fluids Conference

9. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
EU Regulation
9
The EU F-Gas regulation 517/2014 on fluorinated greenhouse gases and repealing Regulation (EC)
No 842/2006 sets binding target also for automotive manufacturers with respect to imported vehicles
High GWP Refrigerants (> 150 GWP) are banned from 2017 onwards on all
New Passenger Cars sold in the European Union
High GWP refrigerants can be used on all others road vehicles (e.g. light
commercial vehicles, Trucks, …) being subject to the «Quota» systems

10. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Thermal Systems
Evolution
opportunities
10

11. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Key Items
11
Improvement directions
• Auxiliary systems energy demand minimisation
• Synergies among systems managing the increasing complexity
• Cost - effective approach
• Low temperature heat re-use
• New powertrains are demanding refined thermal control (e.g. liquid cooled
charge air cooler) and in case of electrified powertrains also low temperature
cooling, e.g. by means of A/C
• Heat available for cabin comfort will be increasingly lower
• On board chargeable vehicle (BEV and PHEV) need efficient systems
ensuring summer and winter comfort minimising the energy demand to limiting
the impact on electric range
Thermal systems could be an enabler or a constraint
for achieving the new standard of vehicles' efficiency

12. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Thermal Comfort impact over a year on a Battery Electric Vehicle range:
electric range is highly affected thermal system energy demand in winter as
well as in summer from 10% up to the 40%.
Air Conditioning impact on electric vehicle range
12
To fulfill the thermal comfort need the range of an electric vehicle risks to be
seriously affected. The impact can be even more relevant if additional thermal
energy is required to manage the battery and electronics operation
Paris Seville

13. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Dual Loop cooling system concepts
Comparison with standard engine cooling modules
13
Std. Production Dual Layer
S/L Radiator
Single Layer
heat exchangers
Frontend with
heat exchangers
Frontend with
heat exchanger
Frontend with
Thermal Systems and Aerodynamic Solutions for Ground Vehicles - W. Ferraris et al. ATA – Turin 2015

14. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Mild Hybrid Vehicle Thermal System
14
Engine
C
v
P
LowTemperature
Radiator
Intercooler
BSG
Compressor
Cabin
Heater
Evaporator
Exp. Device
High Temperature
Radiator
Active Grid
Shutters Power Electronics
P e-pump
BSG
LT Rad
HT Rad
HT/LT
Rad
Condenser
Intercooler
Liquid Cooled
Condenser

15. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
This approach enables
• To have sealed system (electric compressor)
• The safe use of flammable refrigerant
• The Heat pump function w/o reversing the thermodynamic cycle
Compact Refrigeration Unit (CRU)
15
A/C compressor
Water Cooled
Condenser
Chiller Intermediate
Heat Exchanger
Thermostatic
Expansion Valve
Hot coolant
Cold coolant

16. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Dual loop system for an Hybrid vehicle
16
Engine
C
v
P
P
LowTemperature
Radiator
Intercooler
Liquid Cooled
Condenser
Compressor
Air Coolers
Battery
Cooler
Cabin
Heater
ChillerExp. Device
High Temperature
Radiator
Active Grid
Shutters
P e-pump

17. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Electric Vehicle Thermal System Heating mode
17
C
v
P
P
LowTemperature
Radiator
Air Cooler
Battery
Cooler
Active Grid
Shutters
P e-pump
v
Power
Electronics
E-motor
Range
Extender
A dual loop system enables the opportunity to have
an Heat Pump without reversing the refrigeration
cycle e.g. with a valve system on the coolant side
This approach can be used on a Electric Vehicle to
ensure thermal comfort (summer and winter) and
powertrain thermal management
Compressor
Liquid Cooled
Condenser
Chiller

18. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Conclusions
18
Thermal management is a key factor to face the CO2 challenge
There are opportunities
• to improve the vehicle efficiency integrating properly the thermal
systems and maximizing the synergies with the aerodynamic
performance
• to make the refrigerant a «non issue»
• To enable new functions (e.g. pre-cooling, comfort while idling, …)
This can be achieved even with a cost-effective approach and known
and available technologies just breaking some commonplaces

19. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Contacts
19
Carloandrea Malvicino
EMEA Vehicle Safety and Regulation Compliance
CO2 Emissions Reduction Strategies
E-mail: carloandrea.malvicino@fcagroup.com
FCA Italy S.p.A.
C.so Settembrini, 40 10135 Torino

20. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
DRAFT
BACK UP
20

21. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Fuel Consumption Saving Benefit
Estimation in Europe
21
1% Fuel Saving  570 l/year  855 €/year
Traveled distance: 20’000 km/year
Fuel cost: 1,5 €/l
Fuel consumption: 8 l/100 km
Period: 3 Years
Data sources: EU Eco Innovations Technical Guidelines, Transport & Environment
1% Fuel saving  16 l/year  24 €/year
Traveled distance: 150’000 km/year
Fuel cost: 1,5 €/l
Fuel consumption: 38l/100 km
Period: 3 Years
Heavy Duty Trucks
Average values
Passenger Cars
Average values

22. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Dual Level Cooling System
Liquid cooled charge air cooler and condenser
22
Engine
C
v
P
LowTemperature
Radiator
Intercooler
Condenser
Compressor
Cabin
Heater
EvaporatorExp. Device
High Temperature
Radiator
Active Grid
Shutters
P e-pump
LT Rad
Condenser
Intercooler
HT Rad

23. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Engine cooling module configurations
A segment cooling module comparison
23
Dual Level
(DL)
Single Layer
(SL)
• Overhang reduction
• Weight reduction
• Cost reduction
• Fuel economy
• Better turbo performances
Standard Production
(SP)
SP DL SL
Overhang 80 mm 76mm 42 mm
Single layer
impact
x – 4 mm – 38 mm

24. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Electric Vehicle Thermal System Cooling mode
24
C
v
P
P
LowTemperature
Radiator
Power
Electronics
Condenser
Compressor
Air Cooler
Battery
Cooler
Evaporator
Active Grid
Shutters
E-motor
P e-pump
v
it is possible to manage all the thermal energy
with one system guaranteeing the heat rejection
and thermal comfort both in summer and in
winter without reverse the A/C cycle
Range
Extender

25. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Dual Loop, Single Layer cooling system Architecture
25
Thermal Systems and Aerodynamic Solutions for Ground Vehicles W. Ferraris et al. ATA – Turin 2015
Low Temp.
Section
Switchable
section
High Temp.
Section
Pump
WaterCharge
aircooler
Cabinheater
T
Engine
Electrical
Water Pump
TXV
Evaporator
Intermediate
HeatExchanger
Tank
Water
Condenser

26. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Radiator concept for Dual Loop cooling system
Single Layer vs. Dual Layer
26
Goal: reduce thickness of the cooling module
Reduced overall airflow restrictions  larger airflow
HT radiator unhampered by AC condenser heat rejection  cooler airflow
LT section HT section
16 mm HT radiator
27 mm LT radiator
27 mm
HT/LT radiator
HT section
Thermal Systems and Aerodynamic Solutions for Ground Vehicles W. Ferraris et al. ATA – Turin 2015

27. Latest Technology in Refrigeration and Air Conditioning - XVII European Conference Milano, 9 - 10 June 2017
Off Cycle Credits
27
There are two main schemes in place enabling CO2 credits to technologies
allowing additional CO2 saving (fuel consumption reduction) in real world
Mobile air Conditioning and Thermal Systems are in principle eligible and
• EU ECO Innovation: Industries (manufacturers and suppliers) send
Applications regarding new technologies and testing methodologies that
undergoes to a technical assessment by the EU and if approved it could
become part of Type Approval
• US Off Cycle Credits: the regulation identifies “on table credits” that does not
need further approval and off-table credits that need to be proven effective and
approved by US government. High efficiency HVAC system and components
are already in the list of on table credits
• Both schemes are used as a basis for the other worldwide regulations
• Both Schemes are under revision for the period 2020 - 2030
http://ec.europa.eu/clima/policies/transport/vehicles/cars/documentation_en.htm
https://www3.epa.gov/otaq/regs/ld-hwy/greenhouse/ld-ghg.htm