Air conditioning cycle simulations using a ultrahigh-speed centrifugal compressor for electric vehicle applications

Abstract

Electric vehicles (EVs) are an increasingly popular option to decrease global greenhouse emissions in the transportation sector. The largest limiting factor is their range, significantly decreased by the cooling load required. In conjunction with the shift to incorporating low-Global Warming Potential (GWP) refrigerants in cooling systems, it is critical to reexamine the design of traditional air conditioning (AC) systems. To this end, a model of a cooling system for an EV was created, while incorporating an ultrahigh-speed miniature centrifugal compressor, allowing for the performance comparison of multiple refrigerants. From these simulations, a centrifugal compression system using HFC-134a provided sufficient cooling capacity for the modeled vehicle (13.07 kW) with lower input power requirements (2.05 kW) than a commercial EV AC system. However, this requires improved heat exchanger efficiencies. A straightforward system design may be attainable with lower operating pressures utilizing the low-GWP HFO-1336mzz(Z) while achieving a nearly equivalent cooling capacity (12.39 kW) at reduced power requirements (1.86 kW). Performance and safety tradeoffs were examined for a variety of refrigerants and azeotropic mixtures. The use of azeotropic refrigerants increased the cooling capacity and energy efficiency compared with the individual components, but with the tradeoff of higher pressure and compressor exit temperatures. Overall, this effort provides specified conditions for EVs while being among the first to demonstrate the potential of low-GWP and low-Ozone Depletion Potential refrigerants in AC systems utilizing ultrahigh-speed centrifugal compressors.