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The paper presents a semi-empirical model to predict refrigerant and lubricant inventory in both evaporator and condenser of an automotive air conditioning (MAC) system. In the model, heat exchanger is discretized into small volumes. Temperature, pressure and mass inventory are calculated by applying heat transfer, pressure drop and void fraction correlations to these volumes respectively. Refrigerant and lubricant are treated as a zeotropic mixture with a temperature glide. As refrigerant evaporates or condenses, thermophysical properties are evaluated accordingly with the change of lubricant concentration. Experimental data is used to validate the model. As a result, refrigerant and lubricant mass is predicted within 20% in the evaporator. However, in the condenser, lubricant mass was consistently under-predicted while refrigerant mass was predicted within 15% error. Moreover, the lubricant under-prediction becomes more significant at higher Oil Circulation Ratio (OCR).

Carbon dioxide (CO2 or R744) is a promising next-generation refrigerant for mobile air-conditioning applications (MAC), which has the advantages of good heating performance in cold climates and environmental-friendly properties. This paper presents a simulation model of an integrated internal heat exchanger (IHX) and accumulator (Acc) using the finite volume method. The results are validated by a group of experimental data collected with different transcritical R744 mobile air-conditioner and heat pump (MHP) systems, and the error was within ±10%. The impacts of refrigerant mass flow rate and operating temperatures on the heat transfer rate of the IHX, improvement on refrigeration capacity and the liquid level in the Acc were studied. Results show that the net benefits of IHX are significant in AC mode, while it helps preventing flooding of the compressor in MHP mode.

This paper presents a model analysis of oil effects on the distribution of two phase refrigerant in a parallel flow microchannel evaporator. A microchannel evaporator model developed and presented earlier (SAE paper 2012-01-0321) is enhanced by inclusion of the thermodynamic and transport properties of refrigerant-oil mixture and their impact on boiling heat transfer and pressure drop characteristics. R134a and PAG oil are selected as the working pair. Viscosity effect and OCR effect on refrigerant distribution are investigated using this model, and the results show that 1) High viscosity is detrimental for refrigerant distribution. 2) As OCR increases, distribution becomes worse; but at very high OCR, distribution becomes better. Some initial experimental results show that distribution becomes worse when OCR changes from 0.1% to 3%.

This paper presents experimental study of periodic reverse flow and induced boiling fluctuations in a microchannel evaporator and their impacts on performance of R134a mobile A/C system. Simultaneous flow visualization and pressure measurements revealed that reverse flow due to confined bubble longitudinal expansion caused periodic oscillations of the evaporator inlet pressure and the pressure drop, and their oscillation magnitude and frequency increase with ambient air temperatures because of higher average refrigerant mass flux and heat flux. Three potential impacts of vapor reverse flow reversal on evaporator performance are identified: 1) mild liquid maldistribution; 2) increased the evaporator pressure drop; 3) reduced heat transfer coefficient. Finally, to mitigate vapor reverse flow impacts, revised flash gas bypass (FGBR) method is proposed: vent and bypass backflow vapor trapped in the inlet header.

This paper presents the study of refrigerant charge imbalance between A/C (cooling) mode and HP (heating) mode of a mobile reversible system. Sensitivities of cooling and heating capacity and energy efficiency with respect to refrigerant charge were investigated. Optimum refrigerant charge level for A/C mode was found to be larger than that for HP mode, primarily due to larger condenser size in A/C mode. Refrigerant charge retention in components at both modes were measured in the lab by quick close valve method. Modeling of charge retention in heat exchangers was compared to experimental measurements. Effect of charge imbalance on oil circulation was also discussed.

With market share of electric vehicles continue to grow, there is an increasing demand of mobile heat pump for cabin climate control, as it has much higher energy efficiency when compared to electric heating and helps to cut drive range reduction. One big challenge of heat pump systems is that their heating capacities drop significantly when operating at very low ambient temperature, especially for those with low pressure refrigerants. This paper presents a way to improve low ambient temperature heating performance by using intermediate vapor bypass with the outdoor heat exchanger, which works as an evaporator in heat pump mode. The experimental results show a 35% increase of heating capacity at −20 °C ambient with the improved system as compared to the baseline, and heating performance factor also slightly increased when the system is working at higher ambient temperature to reach the same heating capacity as the baseline.

A traditional method of controlling evaporator superheat in a vapor compression air conditioning system is the thermostatic expansion valve (TXV). Such systems are often used in automotive applications. The TXV depends on superheat to adjust the valve opening. Unfortunately, any amount of superheat causes that evaporator to operate at reduced capacity due to dramatically lower heat transfer coefficients in the superheated region. In addition, oil circulation back to the compressor is impeded. The cold lubricant almost devoid of dissolved refrigerant is quite viscous and clings to the evaporator walls. A system that could control an air conditioner to operate with no superheat would either decrease the size of its existing evaporator while maintaining the same capacity, or potentially increase its capacity with its original evaporator. Also, oil circulation back to the compressor would be improved.

This paper presents the experimentally obtained performance characteristics of an air conditioning-heat pump system that uses heat exchangers from a commercially available Nissan Leaf EV. It was found that refrigerant charge needed for cooling operation was larger than that for heating function with the test setup. The effects of: a). indoor air flow rate, b). outdoor air flow rate, and c). compressor speed on heating capacity and energy efficiency were explored and presented. Appropriate opening size of expansion valve that controlled subcooling for better energy efficiency was discussed and results were presented. Expansion valve opening size also strongly affected charge migration. Warm-up tests at different ambient conditions showed the necessity of a secondary heater to be reserved for very low ambient temperature.

Lubricant in compressor usually flows out with refrigerant. Thus, it is evitable for lubricant to be present in the heat exchanger, which significantly affects the heat exchanger performance. This paper is to investigate the effects of PAG oil on R134a distribution in the microchannel heat exchanger (MCHX) with vertical headers and to provide a tool to model R134a (with oil) distribution and its effects on MCHX capacity. The flow configuration in MCHX under the heat pump mode of the reversible system is mimicked in the experimental facility: refrigerant-oil mixture is fed into the test header from the bottom pass and exits through the top pass. It is found that a small amount of oil (OCR=0.5%) worsen the distribution. But further increasing OCR to 2.5% and 4.7%, the distribution becomes better.