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Oil in circulation (OIC) in a vehicle AC system is an index to demonstrate the system having a proper oil charge. A well lubricated compressor is key for AC system, as it relates to compressor durability. The challenge that climate control development engineering faces is how to correlate OIC from test to test (test stand to vehicle level etc.). In this study, a method to correlate vehicle AC system OIC from test-to-test, stand to vehicle is developed. The study found that oil charge amount ratio, refrigerant mass flow ratio, and vehicle engine speed ratio are the key factors to correlate the test results such as stand versus vehicle, vehicle test A versus test B etc. To further reflect compressor oil lubrication conditions, compressor compression index (polytropic number) is computed for the different testing, and the ratio of compression index is also introduced to the correlation. The method accuracy was validated by multiple vehicle/stand tests.

The majority of vehicle AC system warranty costs are a result of compressor replacement caused by excessive wear and seizure-related failures. In today's environment, compressor manufacturers can control manufacturing process well and maintain a stable product quality. Thus, compressor durability heavily relies on a durable AC system design. Both vehicle compressor suppliers have a variety of procedures and test methods to evaluate AC system and compressor durability. Often times, we still see very different compressor warranty return rates (one higher, the other lower) for the same compressor from the same production line in similar vehicle AC systems. In many cases, both AC systems passed vehicle and component durability tests. In addition, compressor manufacturing process quality was controlled well. The question remains why is there such different compressor warranty return rates?