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The automotive air-conditioning (AC) components fitted on passenger car having high vibration make significant impact on vehicle noise and harshness inside the cabin. Hence, it is necessary to reduce the vibrations within the permissible limit. This can be done by improving dynamic behavior of the assembly under vehicle fitments. The present paper explains about design improvement carried out on the condenser assembly to increase strength of the mounting brackets as well as to reduce the noise level by reducing the vibrations. Modal frequency response analysis has been performed on the existing condenser and found that there was relatively high vibration on the assembly due to low stiffness of the bracket. From the acoustic analysis, it was observed that the noise is occurring due to high vibration at resonance condition. By doing the design changes on the assembly, modal frequency increased relatively. Accordingly, noise level also reduced.

A Finite Element Method (FEM) is used to determine the modal frequency and structural integrity of the automotive condenser assembly, whereas the experimentation (modal and dynamic) are performed using electro-dynamic vibration shaker for vibration durability. In this paper, numerical and experimental modal & dynamic analysis are discussed to derive the modal properties (mode shapes & modal frequencies) and dynamic properties (stresses & deflections) of condenser assembly. The effects of vibration occurring due to dynamic interaction between vehicle and road, vibration transmitted from machinery to its supporting structures thereby interfering with their performance, damage as well as malfunction and failure due to dynamic loading and cyclic loading. In this work, author compared modal frequencies as well as the life cycle of the condenser assembly through FEM and experimentations.

A Fiber-reinforced plastic (FRP) is category of composite plastics that specifically use fiber materials to mechanically enhance the strength and elasticity of plastics. A Compressor mounting bracket is mounted on the base of fiber-reinforced plastic material and subjected to very high stresses due to inertia, static and dynamic load coming from compressor as well from other sub-assemblies. In order to make the compressor bracket and FRP base plate more robust under the dynamic load, the operating frequency should be far away from the assembly and sub-assembly’s resonant frequencies and thereby, the component design should be robust to sustain that much of external excitation load coming from the various sources includes self motor rotation, road load and from many sub-assemblies. The Primary goal of this Paper is to strengthen the FRP base plate and compressor mounting bracket in order to sustain the vibration load, maximizing the modal frequency of assembly and sub-assemblies.