Technology evaluation report for auxiliaries for e-A/C, e
Transcription
Technology evaluation report for auxiliaries for e-A/C, e
Responsible (Name, Organisation) Walter Ferraris, CRF DELIVERABLE REPORT Date WP No April 2013 2200 Issuer (Name, Organisation) Walter Ferraris, CRF Tytus Adamczewski, SOLARIS Subject: Technology evaluation report for auxiliaries for e-A/C, e-compressor and e-heating Page 1(30) Report No D2200.1 Dissem. Level PU HYBRID COMMERCIAL VEHICLE (HCV) DELIVERABLE D2200.1 TECHNOLOGY EVALUATION REPORT FOR AUXILIARIES FOR e-A/C, e-COMPRESSOR AND e-HEATING Summary In this document the significant activity regarding the WP2200 (Task 2210) will be described. CRF and Solaris are involved in the investigations on the electric A/C system, electric air compressor and electric heating in order to define the HCV project improvements for these components. The target is to update and complete the know-how in order to have the right tools and the right competences to project a more efficient system. Conclusion The technical scenario proposed in this document shows some of the most promising solutions and components for high efficiency e-A/C, e-Compressor and e-Heating systems focused on the new traction vehicles application. This is a good starting point for the auxiliary systems that will be developed in the HCV project for the hybrid vehicle. In the Task 2220 we will evaluate all the best component solutions by model and simulation in order to define the most efficient solution to implement in the prototypes. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 2 of 30 Table of content Summary ............................................................................................................................... 2 Conclusion ............................................................................................................................ 2 Table of content..................................................................................................................... 3 Table of figures ..................................................................................................................... 4 List of Tables ......................................................................................................................... 4 1 Electrical Air Conditioning .............................................................................................. 5 1.1 Introduction ............................................................................................................. 5 1.2 A/C Compressor for hybrid and electric vehicle ....................................................... 5 1.2.1 DENSO solution ............................................................................................... 5 1.2.2 SANDEN solution ............................................................................................. 7 1.2.3 DELPHI Solution .............................................................................................10 1.3 1.3.1 Intermediate Heat Exchanger ..........................................................................12 1.3.2 Dual loop solutions ..........................................................................................13 1.4 2 3 Plant Solution .........................................................................................................12 Costs Analysis........................................................................................................15 Electrical air compressor ..............................................................................................17 2.1 Technology description & evaluation ......................................................................17 2.2 Technology description & evaluation ......................................................................20 2.3 Applied solution HYDROVANE V6T .......................................................................21 2.4 Costs analysis ........................................................................................................22 Heating system and air conditioning system in hybrid busses.......................................23 3.1 Air- conditioning system .........................................................................................23 3.2 Water heating system with Grayson electric heating device ...................................24 3.3 Possibility of application of the electric heating system...........................................25 3.4 Control of heating system components...................................................................29 3.5 Costs analysis ........................................................................................................30 HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 3 of 30 Table of figures Figure 01 – DENSO compressor production chronology................................................................. 6 Figure 02 – Compressor Comparison .............................................................................................. 6 Figure 03 – Left: SANDEN Hybrid Compressor; Right: The Hybrid compressor scheme .............. 7 Figure 04 – C.O.P comparison under the same Refrigerating Capacity & Technical Info .............. 7 Figure 05 – SANDEN F655 electrical prototype compressor .......................................................... 8 Figure 06 – Refrigerating Capacity and C.O.P. ............................................................................... 9 Figure 07 – C.O.P comparison under the same Refrigerating Capacity ......................................... 9 Figure 08 – Electrical motor, compressor and CAD installation and coupling .............................. 10 Figure 09 – System Architecture .................................................................................................... 10 Figure 10 – GM solution ................................................................................................................. 11 Figure 11 – NP A/C loop with IHX .................................................................................................. 12 Figure 12 – IHX behaviour ............................................................................................................. 13 Figure 13 – Plate brazed water condenser .................................................................................... 14 Figure 14 – Compact Refrigeration Unit ........................................................................................ 14 Figure 15 – Left: Bidirectional expansion valve; Right: Inversion valve ........................................ 15 Figure 16 – Components costs analysis ........................................................................................ 16 Figure 17 – Hydrovane V6T vane – compressor ........................................................................... 21 Figure 18 – Dimension and performance of Hydrovane V6T vane compressor ........................... 22 Figure 19 – Main parts of Hydrovane V6T vane compressor ........................................................ 22 Figure 20 – Grayson heating device .............................................................................................. 24 Figure 21 – Side profile of Grayson heating device ....................................................................... 24 Figure 22 – Heating system of bus with electric heating device .................................................... 25 Figure 23 – PEDRO SANZ electric heater ..................................................................................... 26 Figure 24 – Diagram of connecting the PEDRO SANZ heater ...................................................... 27 Figure 25 – PEDRO SANZ frontbox............................................................................................... 27 Figure 26 – Heaters arrangement in URBINO HIII 18 ................................................................... 28 Figure 27 – Spheros thermo heater ............................................................................................... 28 Figure 28 – Heating system with CUMMINS ISBe E4 at the rear with AC system. ...................... 30 List of Tables Table 1 - Technical information on the of the compressor and refrigerant circuit ........................... 8 HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 4 of 30 1 Electrical Air Conditioning 1.1 Introduction The worldwide scenario of road transport is moving towards a new generation of vehicles with enhanced power train able to guarantee a further increase of the fuel economy. This is mainly due to the CO2 reduction initiatives and to the change of the world energy economy caused by the rapid increase of the developing countries and the related increase of fossil fuel demand. One of the technical solutions guaranteeing a significant fuel economy improvement is represented by the so-called micro-hybrid power train able to operate the Stop & Start function and, in the most sophisticated version, to recuperate the braking energy. The Stop & Start function allows stopping the engine automatically at car idle condition. This feature presents a problem because current A/C-compressors would also stop and so the temperature inside the vehicle rises. As hybrid vehicles also have mostly sufficient electrical energy available there is the possibility to run the compressor by an electric motor. Anyway, the hybrid and pure electric traction will be probably the new generation of power train in order to warrant the lower environmental impact. All the vehicle auxiliaries systems have to be reviewed in order to assure the same performances as the actual production vehicle in terms of comfort and usability, but with a lower power consumption to minimize the impact on vehicle autonomy. In this section we will focus on the A/C system and we will provide an overview on the solutions realized by some car makers which are using hybrid or electrical compressor systems and some innovative solutions on the plant lay-out in order to improve the efficiency. The fuel saving potential of the individual technologies including the pros and cons have been evaluated in the Task 2220 and presented in the deliverable “D2200.2: Detailed specifications of auxiliaries for e-A/C (CRF), e-compressor and e-heating (Solaris)”. 1.2 A/C Compressor for hybrid and electric vehicle Following the introduction above, we will describe the main solutions adapted in hybrid or electrical vehicles. The main component that has to be reviewed in order to adapt the A/C system on the new alternative traction vehicle is the compressor. Toyota, Honda and some others are using solutions from DENSO, SANDEN and DELPHI described on the following pages. 1.2.1 DENSO solution DENSO TS started the electrical compressor production in year 1995. Actually DENSO has three compressors with different sizes and component characteristics available. The development chronology is shown in Figure 01. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 5 of 30 Figure 01 – DENSO compressor production chronology The main features of the DENSO compressors are: integrated Inverter Inverter cooled directly by suction refrigerant Oil separator in order to improve the system capacity and the compressor lubrication CAN communication to simplify the compressor management and diagnostics The three compressors performances are shown and compared in Figure 02. Figure 02 – Compressor Comparison *note1 : pd/ps = 1.47/0.196MPaG SC = 5°C SH=10°C *note2 : pd/ps = 1.47/0.196MPaGSH=10°C HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 6 of 30 The noise measurements are performed with the compressor mounted on rigid bracket and the measurement point is 1m from the side of the compressor. 1.2.2 SANDEN solution SANDEN has developed some hybrid compressor systems with different sizes and moreover some fully electric compressor. Figure 03 – Left: SANDEN Hybrid Compressor; Right: The Hybrid compressor scheme The hybrid compressor has two compression mechanisms and each compression mechanism is driven independently. One is driven by the engine crankshaft pulley belt and the other by an integrated electrical engine. The scroll compression mechanism, which has superior efficiency, is used for both. Both drives, crankshaft pulley belt and e-engine, are used to accelerate the cool down. Eengine drive is used for idle stop cooling The key factor to minimize packaging volume was to reduce, as small as practicable, both the belt drive and the e-engine drive. A 15 cc electrically driven scroll compressor gives enough performance to keep the passengers comfort level during idle stop condition. A 75 cc belt driven compressor adds enough performance to achieve good pull down results. Three-phase connector Hermetic plate Voltage from inverter Scroll on belt driven side Scroll on motor side Rotor Model Name Type Stator Refrigerant:HFC134a Oil: Ester Fixed scroll Beltside Driven side (75 cc) Belt driven (75cc) Electric driven side (15cc) Displacement Maximun allowable Maximun down shift speed Refrigerant Oil Motor Mass HBC75115 2 Scroll Hybrid Belt Driven 75 cc/rev Motor Driven 15 cc/rev Belt Drive 9000 rpm Motor Drive 6000 rpm Belt Drive 12000 rpm Motor Drive N/A HFC - 134a SE - 10Y DC Brushless motor 9 Kg Electric Driven side (15 cc) Figure 04 – C.O.P comparison under the same Refrigerating Capacity & Technical Info HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 7 of 30 SANDEN has also developed a fully electric compressor. At the moment the system is in prototype phase, but in the next months the production of an evolution of this component will be started. The main prototype data is shown in the Table 1 and figures: Figure 05, Figure 06, Figure 07. Table 1 - Technical information on the of the compressor and refrigerant circuit Motor Displacement Max. Speed Refrigerating Capacity Rated Voltage Range Refrigerant / Oil Mechanical Dim WxHxD [mm] Mass DC Brush-less 27cc/rev 8500rpm Please refer below graph. 300V to 400 V HFC134a / SE-10 222x120x120 7.6kg (include oil 0.15kg) The compressor, similar to the model produced by DENSO, is equipped with an internal inverter. The inverter basic functions are: - - Motor speed control – By detecting the rotor magnet position with sensor-less method, compressor speed will be controlled to the target speed indicated by the vehicle ECU. CAN communication o Target speed, comp. ON/OFF signal from vehicle ECU o Power consumption, comp. actual speed, failure mode detection from motor driver Failure mode detection – Failure mode detection of each sensor and overcurrent protection Figure 05 – SANDEN F655 electrical prototype compressor HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 8 of 30 Figure 06 – Refrigerating Capacity and C.O.P. Figure 07 – C.O.P comparison under the same Refrigerating Capacity The performance of the electric SANDEN compressor is shown in Figure 06 and Figure 07. The test conditions utilized in order to perform the component characterization shown in these two figures are: - Pd / Ps = 13.7 / 2.0 MPa*G SH / SC = 10 / 5 K where: Pd = Discharge pressure Ps = Suction pressure SH = Super Heat SC = Subcooling HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 9 of 30 1.2.3 DELPHI Solution DELPHI has developed a different system for a particular application. To provide an A/C system for an electric minibus realized for Dubai mission, Delphi has installed a roof unit equipped with a standard belt compressor (DELPHI SP15) driven by an electrical brushless engine. Figure 08 – Electrical motor, compressor and CAD installation and coupling The electrical engine is a brushless permanent magnet application. It is operated by on/off mode with CAN protocol in order to optimize the energy consumption. The electronic board needed for motor management (operating at 24 volts) is integrated in the electric engine and it is capable to manage supply voltages from 96 up to 700 volts DC. This configuration gives, as final result, a very compact compressor & motor unit, reducing the overall dimensions and weight dramatically. Furthermore it is required for the development of a compressor & motor units family, related to wide range of application: car, minibus, midibus, bus etc… Some other system key factors are: New electronic expansion valve Integrated electronic board that gives to the designer the flexibility to optimize the best ratio between A/C cooling performance and energy consumption Figure 09 – System Architecture The target vehicle market was Abu Dhabi so the operating condition was: Max external temperature: 52 °C Max HR%: 90 Solar load radiation: 1100 W/m2 HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 10 of 30 The system characteristics are: Vehicle voltage supply operative range: 260 - 320 volts Power A/C system supplied by the same vehicle voltage, without inverter Max energy consumption: 8 KW at 320 volts equivalent to 25 A Max internal temperature: 27 °C Weight: less than 160 Kg Overall Size (WxHxD) : 2030x1280x230 [mm] Some other car makers have used similar solutions as the described here. CRF doesn’t have details about the compressor typology and construction. The information about these solutions has been found in the literature and it’s been included with the same detail level. The major example in 2010 is MY Ford’s hybrid vehicle. The dual scroll compressor, installed until 2009, was changed by an electric belt driven compressor like the used in the Prius vehicle. General Motors has also realized some similar solutions for its hybrid brand as presented on Figure 10. Figure 10 – GM solution HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 11 of 30 1.3 Plant Solution In order to complete the overview of the state of the art solutions regarding the A/C systems some details about the new plant configuration solutions related to the electrical and hybrid electric vehicles are presented in the following paragraphs. 1.3.1 Intermediate Heat Exchanger In the last years a lot of car makers have started to use the IHX solution as shown in Figure 11 in order to improve the A/C efficiency. In this kind of solution, the low temperature refrigerant gas at the evaporator outlet cools the liquid refrigerant from the condenser outlet, thus performing an internal energy recovery. REJECTED HEAT CONDENSER COMPRESSOR Refrigerant Loop ENGINE BAY CABIN EVAPORATOR EXPANSION DEVICE Figure 11 – NP A/C loop with IHX The effects of this kind of heat exchanger solution on the thermodynamic cycle are shown in Figure 12. The effects are mainly on the pressures, where the gap between the High Pressure and the Low Pressure is reduced. Providers of this typology of heat exchangers are: DENSO DELPHI TI automotive MAFLOW The pipe design can be developed in order to fit the other components and to find the best compromise between the pressure drops and the pipe length. Considering that more pipe length is better in terms of efficiency and heat exchanged longer piping is not problematic. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 12 of 30 Figure 12 – IHX behaviour 1.3.2 Dual loop solutions The following points summarize the benefits of using dual loop solutions: Reduce the refrigerant quantity and therefore the possible leakages Reduce the dimension of the A/C loop Reduce the space on the front-end Improve the security with the new refrigerant usage. Take advantages by the thermal inertia for the START & STOP solutions There are a lot of plant solutions that can be used. In the following paragraphs some details about the most important solutions are shown. 1.3.2.1 Smart Cooling Solution This solution allows removing the condenser from the frontend and all the other air – fluid heat exchangers. Using a low temperature cooling circuit (working temperature around 60 °C) it is possible to supply the refrigeration to all the components that need it. The solution allows re-organizing the engine bay and managing a new solution on the front-end in order to improve the pedestrian collision normative. The new condenser for the A/C loop will be a plate brazed water condenser as shown in Figure 13, which is compact and has the same efficiency as the air side heat exchanger. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 13 of 30 A list of currently available suppliers: Luvata Onda Alfa Laval GEA Denso DANA Figure 13 – Plate brazed water condenser 1.3.2.2 Secondary Loop Solution The secondary loop solution has been developed to limit the coolant volume flow into the engine bay. The refrigerant HFO - 1234yf is chosen by the most important car makers in order to replace the r134a and to respond to the new 2011 Global Warming Potential (GWP) European normative. This fluid has a good GWP, but is flammable. The Secondary Loop solution allows using the refrigerant fluid for the water refrigeration, and manages the cabin air refreshing and dehumidification with an air cooler. Combining the two solutions (Smart Cooling and Secondary loop) it is possible to develop a Compact Refrigeration Unit (CRU) with smaller refrigerant quantity, compact dimension and with all the advantages provided by the two separated solutions. RADIATOR EXP VASE PUMP CONDENSER CMP CHILLER EXP VASE PUMP AIR COOLER Figure 14 – Compact Refrigeration Unit HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 14 of 30 1.3.2.3 Heat Pump To complete the scenario, we want to discuss about the possibility to finalize a civil application heat pump (like the heat pump used in the fan coil configuration) which can be used widely in an automotive solution. This idea was born in order to find an efficient solution for the cabin heating and refreshing in the electrical vehicles. With the pure electrical traction there are few heat sources which are able to supply the heat for the cabin heating. Therefore the possibility to perform a thermodynamic cycle inversion in order to use the cabin heat exchanger as a dual function component has been studied: In summer mode like an evaporator In winter mode like a condenser In this way it would be possible to realize both functions with one system. The main components needed are the inversion valve and the bidirectional expansion valve (Figure 15) that can be replaced by an orifice solution. These components are actually available for the fan coil systems, but some suppliers (SANDEN and DENSO) are currently developing and investigating a modified version for a car application. Figure 15 – Left: Bidirectional expansion valve; Right: Inversion valve On the other hand there is some optimization of the heat pump systems required due to the following two main problems: The evaporator icing on the frontend of the vehicle The fogging in the cabin (when it is used in the heat pump mode there is no dehumidification possibility) CRF considers the heat pump to be a potentially good solution in order to realize the heating function on the electrical vehicle without any additional electrical heater or booster. 1.4 Costs Analysis In the first steps of the project, we have also tried to evaluate the costs of each of the components, in order to have an overall cost estimation of the system. Figure 16 shows the component costs of the Heat Pump system compared with a standard production system. It has to be considered that the Heat Pump system has been quoted for a small number of pieces/year (20 - 30 pieces). For this reason the final cost is currently not comparable to a HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 15 of 30 standard production air conditioning system. Anyway the new solutions make an improvement in many aspects: Heat functionality without an additional system and without any other thermal sources Possibility to reduce the pipe length and develop a more compact layout in the enginebay Possibility to reduce the refrigerant charge with many collateral advantages in terms of leakage and refrigerant cost (1234yf ready) The Heat Pump system works also when the vehicle is stopped Component for HCV Project NP [€] Components Heat Pump Cost investigation [€] Actual costs Technical description Cost source Prototype Costs CDS 26 ONDA 180 HT RAD 20 DENSO 20 47,2 AUTOCLIMA 27 400 DENSO 1000 CLIMA PIPES Compressor Inversion Valve / / RANCO 34 TXV / 10 DANFOSS 39 17,5 Fiat HVAC 12,5 AC REFRIGERANT Total 520,7 1312,5 Figure 16 – Components costs analysis Legend: CDS = Condenser HT RAD = High Temperature Radiator TXV = Thermostatic eXpansion Valve AC = Air Conditioning HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 16 of 30 2 Electrical air compressor 2.1 Technology description & evaluation Presently three kinds of air compressors are available: reciprocating compressor, vane compressor and screw compressor. They can be powered either mechanically or electrically. In the first case the power is transmitted from the diesel engine using a V-belt while electrically driven compressors are equipped with a built-in electric motor. This innovative solution has many advantages and is therefore described in this report. The electric vane compressor is also suggested by the hybrid system supplier thus SOLARIS will mainly focus on this solution for further development activities. A review of features, benefits and disadvantages of the air vane compressor is given below: General Advantages Simple design Integrated design Proven technology No air receiver Benefits - easily understood - user friendly - low noise level - minimal leak points - no air receiver - easier to maintain - total reliability - no unexpected failures - Reduced installation cost Direct drive (1450 rpm) Advantages No gears, belts or pulleys No drive losses Fewer moving parts and low running speed Low noise level No radial loads on bearings Benefits - minimal maintenance - minimal energy costs - less component stress and generated (wasted) heat - flexibility of location - no replacement bearing costs HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 17 of 30 Only one major rotating part Advantages Simple design Simple to manufacture Benefits - designed reliability - accurate and long lasting components Low noise level (66 dBA) Advantages Allows sitting close to point of use No need for special acoustic cover Lower noise pollution 100% on duty for 100% of time Advantages Continuity of pressure and volume No need to oversize Benefits - lower installation cost - lower total cost - no noise related complains - productive operator Benefits - guaranteed productivity - no time loss - minimum total cost - more profit Built-in aftercooler Advantages Deliver air with temperature not more than 10°C above ambient Majority of condensate removed before dryer Reduced footprint Benefits - size-optimized dryer - lower total cost - less work for dryer - less space required HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 18 of 30 Plain white metal bearings Advantages No specified change period More tolerant to arduous condition Pressurized oil circulation Advantages No mechanical pump Consistent oil circulation Immediate oil circulation on start up Less to service Benefits - no replacement cost - no unexpected breakdowns - last longer Benefits - no mechanical pump failures - optimum oil supply to key areas - total reliability - no non lubricated components - long lasting compressor - quicker servicing Option of continuous run control Advantages Compressor can be sized to match needs Constant delivered air pressure Less stress on drive components Best for continuous high demand No need for air receiver Benefits - minimal total cost - accurate control of process - lower maintenance and repair cost - minimal energy cost - lower installation cost - no inspection downtime The main disadvantages of vane compressors is their availability (limited number of suppliers), and hence the high price. But on the other hand rotary vane compressors have many advantages as mentioned above and additionally the longest durability while delivering the same air quality as the screw compressors. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 19 of 30 2.2 Technology description & evaluation This chapter gives some information on the comparison of the vane and screw compressors. Compressor construction Vane compressor Integrated - unique - minimal connections - simple - silent as standard Direct drive - no efficiency losses - no replacement costs - reliable - limited noise - less components Controls Vane compressor Servo - continuous run - smooth system pressure - no receiver required Regulated speed - standard inverter - standard compressor - standard motor - optimum motor cooling Screw compressor Direct control - load / unload - fluctuating system pressure - receiver required Regulated speed - special technology - high speed air-end - special motor - possible overheating Life Vane compressor 100 000 hrs life minimum Plain white metal bearing Slow speed (1450 rpm) Low stress Screw compressor Not-integrated - indistinguishable - many connections - complicated - extra silencing required Belt/gear drive - increasing efficiency losses - regular replacement costs - unreliable - noisy - more components Screw compressor 30 000 hrs life maximum Roller bearing High speed (3000 rpm) High stress Efficiency Vane compressor 113,3 dm3/min Lower HP more efficient Screw compressor 113,3 dm3/min Higher HP more efficient HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 20 of 30 Life cost Vane compressor Similar overhaul costs Replacement of air-end never required Similar energy cost Similar regular maintenance cost Screw compressor Similar overhaul costs Replacement of air-end every 30 000 hrs. Similar energy cost Similar regular maintenance cost 2.3 Applied solution HYDROVANE V6T Nowadays electric air compressors (e-compressor) are more often used in the automotive industry. The e-compressor provides air pressure even during “idle” stops (when the engine shuts down to save fuel and emissions). This maintains the functionality of the pneumatic system while reducing fuel consumption. SOLARIS expect that application of the new electric air compressor will reduce the fuel consumption of the bus by ~10% as well as improve the emissions of noxious substances. For the HCV project the electrically driven vane-compressor V6T (Figures 17 and 18) produced by Hydrovane was selected. The selection is based on the benefits of these type of compressor compared to other compressors (especially screw compressor) as described in paragraph 2.1. Figure 17 – Hydrovane V6T vane – compressor The main technical data of the proposed e- compressor is presented on the Figure 18 and some information on the main parts of the compressor is shown on Figure 19. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 21 of 30 Figure 18 – Dimension and performance of Hydrovane V6T vane compressor 1 – Air filter 2 – Rotor 3 – Slats 4 – Oil separator 5 – Oil cooler 6 – By-pass oil nozzle Figure 19 – Main parts of Hydrovane V6T vane compressor 2.4 Costs analysis Costs were calculated for a prototype unit. Because of common use of listed elements the cost is exactly the same as a standard system price. Component for HCV Project Component Cost source E-compressor HYDROVANE V6T TSSP HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 Prototype costs [€] 1640 page 22 of 30 3 Heating system and air conditioning system in hybrid busses Air conditioning and heating systems presented in this paragraph concerns the articulated bus “Urbino 18 m” and consist of the following units: combustion heating device heaters and convectors air-conditioned front box air-conditioned passenger compartment driver The components presented below were proposed by manufacturer solution for articulated buses and were examined for the purpose of the HCV project. The main reason for proposing this solution were related to low weight of the individual systems compared to other, the sufficient total efficiency and availability on the market in the Central and Eastern Europe. Currently water heating is used in the buses. The liquid is heated up by the components in the engine cooling system and additionally by another heating device (combustion of fuel). From this point the liquid runs to individual receivers, such as: Pedro Sanz convectors – heating power Q80 - 0,7 kW/1m convector’s length Aurora Teddy heater (passenger space) – heating power Q80 - 7,2 kW Air-conditioned frontbox Aurora – heating power Q80 – 16,9 kW Optional Konvekta roof heating – heating power Q100 – 30 kW Total heating power in the whole vehicle depends on the number of receivers. SOLARIS predicts that fuel consumption with buses contained an electrical heating will be decreased by about 8% and as also emissions of noxious substances will be decreased by about 8%. 3.1 Air- conditioning system The air conditioning system consists of the device for cooling/heating passenger compartment and driver cabin. The Air Conditioning system Konvekta 2xUL500 is proposed mainly due to the low weight of the UL500 unit of 109 kg. The performance of one unit is not sufficient for articulated bus thus 2 units have been proposed. There is also possibility to use one bigger unit but due to the hybrid installation on the roof there was not enough space to assembly it. Air conditioning system 2xUL500 consists of two units UL500 with BOCK compressor powered by belt transmission in the engine. Konvekta 2xUL500 air-conditioning parameters: cooling power – 48 kW heating power – 60 kW evaporator blower’s rated flow rate – 8640 m3/h cooling medium – R134a Aurora air-conditioned frontbox – cooling power 8,4 kW, rated air flow 720 m3/h HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 23 of 30 Air-conditioning system 2xUL500 is equipped with brushless condenser fans and brushless blower evaporators. Cooled or heated air is distributed evenly in the entire length of the vehicle through air-conditioning ducts, and is blown out above the gangway and side windows. 3.2 Water heating system with Grayson electric heating device The innovative solution which is proposed by Grayson to be applied for the hybrid bus, is electric heating device instead of a combustion device used as a standard. Developed by Grayson company, a product called Thermal Resistor can be powered by the battery of the vehicle and can be used for heating of the passenger compartment also when the engine is turned off. This provides effective heating of the passenger compartment and the driver cabin, eliminating the need to use the energy derived from fuel. It has an influence on the reduction of diesel consumption, eliminating fuel emission from the heating system and reduction of noise generated by a combustion device. Figure 20 – Grayson heating device Device parameters: Weight 13,5kg Electric power of the device – 10, 16 or 25 kW Indicator of the device resistance to moisture- IP66 Four possible variants of direction of the electrical connections Figure 21 – Side profile of Grayson heating device HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 24 of 30 Figure 22 – Heating system of bus with electric heating device 3.3 Possibility of application of the electric heating system The concept of implementing a fully electric heating system in a bus in the passenger compartment and the driver cabin is completely different from the standard system. Using the heater and PEDRO SANZ frontbox gives such a possibility. This solution has never been used so far in the buses with a diesel engine. This is an environmental concept of a vehicle heating system, reducing the impact of the system on the exhaust emission. The electric heater is powered by additional source of electric energy with alternating current which is possible to be used in hybrid systems. The electric power of the device is 2 kW. Weight of the Pedro Sanz heater device is 2 kg. The main difference between PEDRO SANZ heater (Figure 23) and GRAYSON heating device (Figure 20) is that heater works as hot air blower while GRAYSON heating device needs an infrastructure with heat carrier (fluid) and convectors. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 25 of 30 Figure 23 – PEDRO SANZ electric heater The diagram proposal with PEDRO SANZ electric heater application is shown on the Figure 24 HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 26 of 30 Figure 24 – Diagram of connecting the PEDRO SANZ heater PEDRO SANZ frontbox (Figure 25) similar to the heaters is powered by an additional electric energy source, which is possible to build in a hybrid drive system. Maximum heating power is 23,3 kW and maximum cooling power is 7,1 kW (for R134a cooling factor used). Figure 25 – PEDRO SANZ frontbox The mechanical dimensions of PEDRO SANZ frontbox (fig.25) are: 592x240x404mm (WxHxD) HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 27 of 30 In Figure 26 a sample diagram of a heaters arrangement in a Solaris URBINO HIII 18 is presented. There a six electric heaters proposed as well as one frontbox unit for the heating system of this articulated bus. E-HEATER E-HEATER E-HEATER E-HEATER E-HEATER FRONTBOX E-HEATER Figure 26 – Heaters arrangement in URBINO HIII 18 The thermo heater prototype (Figure 27) developed by SPHEROS will be applied to the vehicle and tested within project task T2200.4. The efficiency of the heater which is shown on Figure 27 is up to 98% and this device has no significant impact on the installation design. Figure 27 – Spheros thermo heater HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 28 of 30 3.4 Control of heating system components The control of heating and air-conditioning systems takes place by means of one ATC WABCO driver, which works automatically, dismissing the driver of vehicle from the necessity of setting the device in the passenger space. The system is equipped with temperature sensors inside and outside of the vehicle, which allows building optimal comfort for passengers. The ATC driver keeps the temperature in the passenger compartment at 22 °C. There is a possibility to change service settings by +/- 2 or +/- 4 degrees. The driver controls the work of 5 heating electro valves: 1x three-way electric valve for frontbox 2x two-way electric valves for heating the passenger compartment (one per each wagon) 2x two-way electric valves for roof heating (one per each wagon) Division of work of heating in two wagons allows for better and more even/uniform steering of temperature inside the vehicle. In the driver’s cabin the driver has the possibility to set individually his working conditions like, temperature, direction and intensity of blow. ATC WABCO system has the possibility of connecting the device with software, allowing diagnosis and the introduction of parameter changes in heating and air-conditioning system. ATC WABCO driver adjustment range: a. direction of the air flow from frontbox b. air temperature from frontbox c. intensity of the blast from frontbox d. „smog” function – internal air circulation e. on/off switch for passenger AC f. on/off switch for driver AC g. on/off switch for heating system in passenger space h. „reheat” function– drying the air inside the vehicle (evaporating of windows) Figure 28 shows the example of water heating scheme with Cummins ISBe E4 Allison drive and air-conditioning system. HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 page 29 of 30 ROOF HEATING ROOF HEATING COOLER HEATING DEVICE ENGINE Figure 28 – Heating system with CUMMINS ISBe E4 at the rear with AC system. 3.5 Costs analysis Costs were calculated for a prototype unit. Because of common use of listed elements the cost is exactly the same as a standard system price. Component Fronbox Heater Thermo Heater Component for HCV Project Supplier Pedro Sanz Pedro Sanz Spheros HCV Hybrid Commercial Vehicle – D2200.1, Rev_0 Prototype costs [€] 1096 226 1985 page 30 of 30