Experimental investigation and numerical simulation on the hysteresis zone of a variable displacement wobble plate compressor

A test system with the variable displacement compressor (VDC) for automotive air conditioning system is built to study the changing rule of piston stroke length (PSL). It is found from our experiments that the critical suction pressure where the PSL starts to decrease is less than that where the PSL starts to increase for the same PSL; between the two critical lines, a hysteresis zone is formed, within which all the steady-state points fall and there is a multiple-valued relationship between VDC parameters; and the PSL is kept invariable when the VDC parameters change within the hysteresis zone. In order to find out the reason causing the hysteresis zone and to analyze the influence of the compressor parameters on the hysteresis zone, a steady-state mathematical model of VDC is developed and verified by our experimental data. The theoretical analysis indicates that the hysteresis zone is caused by the frictional forces among the moving components of VDC, and the greater the frictional forces, the broader the hysteresis zone and the larger the changing range of suction pressure. The influence of the discharge pressure and rotary speed on the hysteresis zone is that the hysteresis zone moves in the direction of the suction pressure decreasing along with the increase of the discharge pressure or rotary speed.     

Modeling and experimental evaluation of an automotive air conditioning system with a variable capacity compressor

A steady state computer simulation model has been developed for refrigeration circuits of automobile air conditioning systems. The simulation model includes a variable capacity compressor and a thermostatic expansion valve in addition to the evaporator and micro channel parallel flow condenser. An experimental bench made up of original components from the air conditioning system of a compact passenger vehicle has been developed in order to check results from the model. The refrigeration circuit was equipped with a variable capacity compressor run by an electric motor controlled by a frequency converter. Effects on system performance of such operational parameters as compressor speed, return air in the evaporator and condensing air temperatures have been experimentally evaluated and simulated by means of developed model. Model results deviate from the experimentally obtained within a 20% range though most of them are within a 10% range. Effects of the refrigerant inventory have also been experimentally evaluated with results showing no effects on system performance over a wide range of refrigerant charges.     

A mathematical model of variable displacement swash plate compressor for automotive air conditioning system

A mathematical model of control mechanism used in the variable displacement swash plate compressor (VDSC) is developed firstly based on the force balance equation, mass and energy conservation equation. The model of moving components dynamics is developed then by analyzing the forces and force moments acting on the pistons and the swash plate. The compression process model is obtained by fitting the data from our experiments. And finally, the steady-state mathematical model of VDSC is developed by combining the three sub-models above. In order to verify the mathematical model, a test bench for control mechanism and the test system for VDSC have been established, and the simulated results agree well with the experimental data. The simulation results show that, like the variable displacement wobble plate compressor, there are four operation modes for the VDSC, i.e. constant rotary speed and constant piston stroke length (PSL), variable rotary speed and constant PSL, constant rotary speed and variable PSL, variable rotary speed and variable PSL, which have included almost all operation modes of the refrigeration compressor in common use. And there is a hysteresis zone and multiple-valued relationship between the compressor parameters when PSL changes.     

Experimental investigation of a CO2 automotive air conditioner

In this study, a CO₂ automotive air conditioner prototype was designed and constructed. The compressor was of swash plate design; the gas cooler and evaporator were made of fin-tubes; a manual expansion valve and an internal heat exchanger accumulator were used. The lubricant, the CO₂ charge, the evaporator outlet pressure, the compressor speed, the air inlet temperature and flow rate of the gas cooler and the air flow rate of the evaporator were varied and the performance of the prototype was experimentally investigated in detail. The cooling capacity, compressor power consumption, CO₂ mass flow rate, and COP value were analyzed. The experimental results showed that the CO₂ system performance was greatly affected by different lubricants; the CO₂ system performance was sensitive to the mass charge; the high side pressure affected the system performance greatly and a high side pressure controller was needed.     

Experimental study on automotive cooling and heating air conditioning system using CO2 as a refrigerant

Recently, as one of the countermeasures against the global warming and energy conservation problems, natural refrigerants such as CO₂ are now paid attention as substitutes for HFCs in automotive air conditioning systems. Also, in recent years because the heat release from the eco-car's engine decreases, there is a problem that the present automotive heating air conditioning system cannot provide sufficient heating capacity.

As an alternative approach, we focused on a solution utilizing a CO₂-based heat pump, whereby the waste heat from the heat pump cycle during dehumidification of the incoming air (referred to as the dehumidifying condition) is recovered and used as an auxiliary heat source instead of an electric heater. Based on this concept, we aimed to develop an effective automotive cooling and heating air conditioning system using CO₂ as a refrigerant.

As the result, a prototype CO₂ automotive cooling and heating air conditioning system for medium-sized cars was successfully developed. With this system, performance superior to that of the present HFC134a system can be achieved.     

Instability of automotive air conditioning system with a variable displacement compressor. Part 2. Numerical simulation

A test system is built first in order to investigate the instability of the automotive air conditioning (AAC) system with a variable displacement compressor (VDC), and hunting phenomena caused by the large external disturbance in the AAC system with a VDC and a thermal expansion valve, and in the AAC system with a VDC and a fixed-area throttling device are investigated experimentally in part 1 of this paper. The experimental results indicate that there also exist the hunting phenomena in the AAC system with a fixed-area throttling device. The system stability is found to be dependent on the direction of the external disturbance, and the system is apt to cause hunting when the condensing pressure decreases excessively since it may cause two-phase state at the throttling device inlet and make a large disturbance to the system. The piston stroke length will oscillate only when the oscillation amplitudes of forces acting on the wobble plate are great enough, otherwise the piston stroke length will be kept invariable, and then the system instability rule is also suitable for the AAC system with a fixed displacement compressor. From the experimental results, it is concluded that the two-phase flow at the throttling device inlet or at the evaporator outlet is the necessary condition but not sufficient condition for system hunting. Finally, a new concept, conservative stable region, is proposed based on the experimental results and theoretical analysis.     

A low data requirement model of a variable-speed vapour compression refrigeration system based on neural networks

In this work a model of a vapour compression refrigeration system with a variable-speed compressor, based on a black-box modelling technique, is presented. The kernel of the model consists of a full customized radial basis function network, which has been developed to accurately predict the performance of the system with low cost data requirement in terms of input variables and training data. The work also presents a steady state validation of the model inside and outside the training data set, finding, in both cases, a good agreement between experimental values and those predicted by the model. These results constitute a first step to go through future research on fault detection and energy optimisation in variable-speed refrigeration systems.     

Modeling and experimental investigation of accumulators for automotive air conditioning systems

A stream analysis model was developed to simulate the behavior of accumulators and their influence on the automotive air conditioning (A/C) systems. It allows a comprehensive steady state simulation with a set of input conditions such as refrigerant vapor mass flow rate and pressure at the inlet of an accumulator. In this study, the refrigerant/oil mixture is R134a/PAG oil which are totally miscible, but could be any air conditioning refrigerant/oil, including carbon dioxide (CO₂)/oil. The model accounts for all major effects inside the accumulator, such as friction, bends, sudden expansion, sudden contraction and heat exchange. The outputs are vapor quality, pressure and temperature at various positions of accumulator. In order to verify the mathematical model, experiments are performed in an experimental setup made up of real size automotive air conditioning components. The simulated results agree well with the experimental data. The simulation and experimental results show an important function of accumulators that is to determine the vapor quality into compressor, and thus has influence on the performance of whole automotive A/C systems.     

Ice slurry: Pressure drop and deposition velocity

Ice slurries are used in indirect refrigeration systems. The storage tank of ice slurry systems decreases the maximum required cooling capacity of the equipment and smooths down the installation consumption. An advantage of ice slurry systems compared to chilled water systems is the higher cooling energy that can be delivered to customers using the same installed pipes. This paper gives a complete investigation of ice slurry pressure drops and deposition velocity. A model for the friction factor, obtained by empirical and semi-empirical approximation, is discussed. A new simple and efficient method is introduced to find the deposition velocity in an ice slurry fluid flow. Finally a variety of experimental results and some theoretical calculations of ice slurry flow patterns are shown.     

Wrap of cylinder and its effect on main features of rotary vane compressor for automobile air conditioning system

The rotary vane compressor has been used in the automobile air conditioning system. One of the key factors of its design is the wrap of its cylinder. From the working principle of this type of compressor, it is explained in mathematics why the wrap is composed of four parts: arc of circle, main curve, and two segments of transit curves, and the conditions that the wrap needs to satisfy are derived simultaneously. At the same conditions, we compared to the gas force F_p, contact force F_nc of the blade head, the force acting on rotor by blades, and the suction volume V_s for three kinds of main curves. The wrap composed of trigonometric function can form the biggest value of V_s, while the least suction volume V_s will be reached as the cubic polynomial is taken. The wrap composed of trigonometric function forms the biggest absolute value of the gas force F_p and the middle peak value of the force acting on rotor by blades, while the least absolute value of the gas force F_p and the biggest contact force F_nc of blade head will be reached as the cubic polynomial is taken. The force acting on the rotor by blades takes the biggest peak value if the main curve is the ellipse curve. The frequency of the force acting on the rotor by blades is the same as the number of blades at the range of the crank angle from 0 to 180°.     

A phenomenological model for analyzing reciprocating compressors

A new model for hermetic reciprocating compressors is presented. This model is able to predict compressor efficiency and volumetric efficiency in terms of a certain number of parameters (10) representing the main sources of losses inside the compressor. The model provides users with helpful information about the way in which the compressor is designed and working.A statistical fitting procedure based on the Monte Carlo method was developed for its adjustment. The model can predict compressor performance at most points with a maximum deviation of 3%.A possible gas condensation on cold spots inside the cylinder during the last part of the compression stroke was also evaluated.     

Test results of performance and oil circulation rate of commercial reciprocating compressors of different capacities working with propane (R290) as refrigerant

In this experimental investigation five R407C positive displacement hermetic reciprocating compressors, covering different capacities, displacement, stroke-to-bore ratios and number of cylinders, have been characterized using propane as refrigerant by means of a specifically designed characterization test rig. Test results have been systematically compared with their R407C reference performance data to obtain a complete picture on changes on the volumetric efficiency and compressor efficiency amongst others. The compressors used POE oil as lubricant and additional oil circulation rate (OCR) tests at steady state conditions were done to evaluate possible effects and differences to the traditionally used mineral oils.     

Numerical simulation of dehumidifying fin-and-tube heat exchangers: Semi-analytical modelling and experimental comparison

The aim of this paper is to present a developed semi-analytical model for the simulation of dehumidifying air–liquid fin-and-tube heat exchangers. The simulation strategy and the mathematical methodology are described in detail. The model is based on -NTU method, and formulated in a compact way for dry and wet surface situations (temperature or enthalpy driven, respectively). Both rating and design procedures have been developed for fully dry, partially wet, or fully wet surface conditions. The model predictions are compared with experimental data obtained on a wavy and a plain finned heat exchanger, giving reasonably accurate results. The limitations of the empirical information used are clearly identified in the work. The aim of this model is to provide a fast but reliable rating and design numerical tool for air–liquid heat exchanger applications.     

Assessment of boiling and condensation heat transfer correlations in the modelling of plate heat exchangers

This paper studies refrigeration cycles in which plate heat exchangers are used as either evaporators or condensers. The performance of the cycle is studied by means of a method introduced in previous papers which consists of assessing the goodness of a calculation method by looking at representative variables such as the evaporation or the condensation temperature depending on the case evaluated. This procedure is also used to compare several heat transfer coefficients in the refrigerant side. As in previous works the models of all the cycle components are considered together with the heat exchanger models in such a way that the system of equations they provide is solved by means of a Newton–Raphson algorithm. Calculated and measured values of the evaporation and the condensation temperatures are also compared. The experimental results correspond to the same air-to-water heat pump studied in other papers and they have been obtained by using refrigerants R-22 and R-290.     

Detailed thermodynamic characterization of hermetic reciprocating compressors

The aim of this paper is the detailed analysis of different well-known thermodynamic efficiencies usually used to characterize hermetic compressors. Attention is focussed on the volumetric efficiency, the isentropic efficiency, and the combined mechanical–electrical efficiency. A procedure is presented to detach these efficiencies into their main components (physical sub-processes) to get deeper insight on the overall behavior.The volumetric efficiency is split into partial efficiencies related to pressure drop and heat transfer effects, supercharging effects, superdischarging effects, leakages, etc. The isentropic efficiency is detached using two different points of view: the work associated to the individual sub-processes (compression, discharge, expansion, suction), and the work associated to the underpressures, overpressures, and between the inlet and outlet mean compressor pressures. Finally, the combined mechanical–electrical efficiency is related to the heat transfer losses/gains, and to the exergy transfers and exergy destroyed.Even though some of the concepts introduced in the paper can be applied to different kinds of compressors, the discussion is specially focussed on hermetic reciprocating compressors. An advanced simulation model developed by the authors has been used to generate data to illustrate the possibilities of the detailed thermodynamic characterization proposed. The criteria developed are useful tools for comparison purposes, to characterize compressors, and to assist designers during the optimization process.     

Experimental performance analysis and modelling of liquid desiccant cooling systems for air conditioning in residential buildings

The paper presents a new desiccant cooling cycle to be integrated in residential mechanical ventilation systems. The process shifts the air treatment completely to the return air side, so that the supply air can be cooled by a heat exchanger. Purely sensible cooling is an essential requirement for residential buildings with no maintenance guarantee for supply air humidifiers. As the cooling power is generated on the exhaust air side, the dehumidification process needs to be highly efficient to provide low supply air temperatures. Solid rotating desiccant wheels have been experimentally compared with liquid sorption systems using contact matrix absorbers and cross flow heat exchangers. The best dehumidification performance at no temperature increase was obtained in an evaporatively cooled heat exchanger with sprayed lithium chloride solution. Up to 7 g kg⁻¹ dehumidification could be reached in an isothermal process, although the surface wetting of the first prototype was low. The process then provides inlet air conditions below 20 °C for the summer design conditions of 32 °C, 40% relative humidity. With air volume flow rates of 200 m³ h⁻¹ the system can provide 886 W of cooling power.A theoretical model for both the contact absorber and the cross flow system has been developed and validated against experimental data for a wide range of operating conditions. A simulation study identified the optimisation potential of the system, if for example the surface wetting of the liquid desiccant can be improved.     

The reliable simple one-dimensional 64-CPWTR model applied to the two-dimensional heat transfer problem of an insulated rectangular duct in an air conditioning or refrigeration system

The heat-transfer characteristics of an insulated long rectangular or square duct are analyzed by using the one-dimensional plane wedge thermal resistance (PWTR) model and plate thermal resistance (PTR) model in this study. It is found that the errors generated by the PWTR model are all positive and the errors generated by the PTR model are all negative. Thus, the combined plate wedge thermal resistance (CPWTR) model generated by paralleling PWTR and PTR models with the proportion factors of α=0.6 vs. β=0.4 (64-CPWTR model) can neutralize the positive and negative errors and obtain very accurate results in comparison with the two-dimensional numerical solutions analyzed by the CFD software. The errors generated by the one-dimensional 64-CPWTR model are within 1% for practical sizes and practical insulated thickness in air conditioning and refrigeration systems. Thus, the engineer can obtain very reliable heat transfer results when applying the one-dimensional 64-CPWTR model to an insulated rectangular duct.     

Simulation model for complex refrigeration systems based on two-phase fluid network – Part I: Model development

Some complex refrigeration and heat pump systems with several condensers and evaporators have been developed for different kinds of application. Traditional simulation models were developed for systems in certain operating modes and they failed in modeling the complex refrigeration systems with uncertainties of heat exchangers function and refrigerant flowing direction. In order to predict the performance of complex refrigeration systems, a simulation model is presented based on the two-phase fluid network. The model is consisted of distributed-parameter model of heat exchangers and connecting tubes, map-based model of inverter compressor and electronic expansion valve (EEV). Based on the characteristic of refrigeration system and fluid network, the three conservation equations, i.e. energy, momentum and mass equations, are solved iteratively. This model can deal with the uncertainty of refrigerant flow direction by separating the solving process of the components and the fluid network model, and therefore can simulate different kinds of complex refrigeration systems in different operating modes and conditions. The model is validated by the experimental data of an inverter air conditioner in heating/cooling operating modes and it shows the error of the model is mainly determined by the error of submodels of components in calculating heat transfer and pressure loss. The model is applied for performance analysis of three kinds of complex refrigeration systems in the accompanying article [Shi W.X., Shao, S.Q., Li, X.T., Yan, Q.S., 2008. Simulation model for complex heat pump systems based on two-phase fluid network: part II – model applications, International Journal of Refrigeration 31 (3), 500–509.].     

Residential CO2 heat pump system for combined space heating and hot water heating

A theoretical and experimental study has been carried out for a residential brine-to-water CO₂ heat pump system for combined space heating and hot water heating. A 6.5 kW prototype heat pump unit was constructed and extensively tested in order to document the performance and to study component and system behaviour over a wide range of operating conditions. The CO₂ heat pump was equipped with a unique counter-flow tripartite gas cooler for preheating of domestic hot water (DHW), low-temperature space heating and reheating of DHW.

The CO₂ heat pump was tested in three different modes: space heating only, DHW heating only and simultaneous space heating and DHW heating. The heat pump unit gave off heat to a floor heating system at supply/return temperatures of 33/28, 35/30 or 40/35 °C, and the set-point temperature for the DHW was 60, 70 or 80 °C. Most tests were carried out at an evaporation temperature of −5 °C, and the average city water temperature was 6.5 °C. The experimental results proved that a brine-to-water CO₂ heat pump system may achieve the same or higher seasonal performance factor (SPF) than the most energy efficient state-of-the-art brine-to-water heat pump systems as long as: (1) the heating demand for hot water production constitutes at least 25% of the total annual heating demand of the residence, (2) the return temperature in the space heating system is about 30 °C or lower, (3) the city water temperature is about 10 °C or lower and (4) the exergy losses in the DHW tank are small.     

Simulation model for complex refrigeration systems based on two-phase fluid network – Part II: Model application

A simulation model of complex refrigeration system based on two-phase fluid network is developed in part I of the paper [Shao, S.Q., Shi, W.X., Li, X.T., Yan, Q.S., 2008. Simulation model for complex heat pump systems based on two-phase fluid network – part I: model development. International Journal of Refrigeration 31 (3), 490–499.]. One same fluid network is used in the model to describe the refrigeration system in different operating modes with the method of the factual and fictitious branches. When there are many heat exchangers with concurrent cooling and heating, the traditional models are not able to define the flowing directions. The developed model, however, whether the initial flowing direction of the connecting branches is right or not, is able to predict the flow and heat transfer. Three typical complex refrigeration systems such as the multi-unit inverter air conditioner, heat pump with domestic hot water and multi-unit heat pump dehumidifier are simulated with the developed model as demonstrations on how to use it. The model can evaluate the influences of one or more parameters on the system performance, which can be used for the optimization of the system by all-condition performance analysis. It is shown that the two-phase fluid network model is effective and convenient for the simulation of different complex refrigeration system, especially for performance analysis, system evaluation, and optimization based on the performance prediction.