Component DevelopmentforJOERN FROEHLING / MARION LORENZ-BOERNERTFRED SCHROEDER / VIPEN KHETARPAL /SRINIVAS PITLAFluid TransportPressure ReliefDevicesFitting TechnologyFlexible HosesService Port / ToolFluidTransportCO2– Design Criteria•Burst Requirement- High side: 32 / 35,2 MPa- Low side: 24 / 26,4 MPa•Materials• Aluminum• Stainless Steel•Sealing Target• < 1g CO2/year•Max. OperatingTemperatures–High side: 180oC–Low side: 120oC•Ambient conditions-40 ... 120oC•Pressure Relief Settings-16 MPa – High Side-12 MPa – Low Side> 42 days60 sec, Prototypes: 90 secTest duration< 154Pressure [MPa]1stday: 180°C2ndday: -40 ... 180°C3rdday: 180°C....ambientTemperature< 1 g CO2/y0,2 g CO2/y (based on He-measurement)RequirementLeakageCO2-PermeationtestHe-leakage testLeakage and Permeation TestCO2- VisteonService Port & CapMaterial of stem: Al or SS•Metal seal•Torx drive (uncommon)•Serviceable–SS housing: 250 re-assemblies with no leak–Aluminum housing: >30 re-assemblies with no leak•Leak rate (SS)–< 0.3 g/y @ 7% duty cycle (without cap)•Sealing cap or dust cap•Safety ring – prevents projectile!!He-Leakage!!Vibration 5 Hz,+/-15mm, -40...120°Ctbd!Contamination!!Torque tolerances!!Pressure cycling 5...15 MPa,225000 cycles, 180°Ctbd!CO2-PermeationAlSSHousingPhase 2 design in development:• Outer surface will be in line with new SAE requirementsCO2- Visteon Service PortCO2- Service Coupler"Similar to R134a coupler"Automatic torque feature"Automatic safety lock"Two rotations to full open"Positive “valve closed” Indication"Ergonomically friendly"Internal seals can be easily replaced"HS and LS couplers according latest SAE valve housingSS, AlSS, SS/Al(Al under development)Material•Serviceable (requires seal replacement)Remarks6 ... 10 Nm25 NmInstallation Torque< 0.5 g/y @7% duty cycle< 0.4 g/y @7% duty cycleLeak Rate (SS)Metal & othersMetalSealer materialPeanutFlare fittingFittingsPeanut fitting –Repeat Assembly Test• Blocks in Al• Different sealers• Sealers were changed after change of torqueRepeat Assembly TestPeanut E340,00,20,40,60,81,00123456Amount of Repeat Assemblies

R744-Leakage [g/y] based on He -measurement6Nm8Nm10Nm12NmRepeat Assembly TestPeanut E6660,00,20,40,60,81,01,21,41,61,82,02,22,40123456Amount of Repeat Assemblies

R744-Leakage [g/y] based on He-Measurements6Nm8Nm10Nm>200 h, 31 Hz,+/- 1,75 mm,90°(no torsion)Vibration180° angleHP: 180°C, 0.5.. 15MPa,LP: 120°C, 0,2...12MPaPressure cyclingdurability+/- 15 ...20 mm, 5 Hz,-40°C...120°C(in the future: max. 180°Cfor HP-side)Torsiondurabilityat 20°C/180°CRequirementsTestBurstHoses Evaluation / 1tbdFlexibilityTest in the CO2-system test rig at different rpmNVH, 180°HP: < 0,2 MPa, LP: < 0,1 MPaRequirementsPressure dropTestHoses Evaluation / 2CO2Steelhose WhistleExample at1500 compressor rpm-100-80-60-40-200204060801000 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000Frequency [Hz]

Acceleration [m/s2]020406080100120140160180200 

# Sound Pressure Level

[dBA]HP hoseLP hoseMicroPressure drop of CO2- Metal hoseson the LP-Side for different suppliers0.000.200.400.600.801.00100 150 200 250 300 350Mass flow [kg/h]

Pressure drop [MPa]LimitCO2-system - Charge trial• Test rig: IAA-Buck (HP/AC-system)• Test sequence:• No „Production“-CV & tool was available• Next step: Test with CO2-CV‘s•Similar process time as R134aTest 28X- ChargeTest 15XXXX- Evacuation- ReleaseTest 30XX- Pressure test with N2RemarkLP-PortHP-PortVariable DisplacementCompressor For R-744VIPEN KHETARPALSRINIVAS PITLAIntroduction"Clutch/Clutchless compressor design"Design Burst Pressure: 34 MPa (highside) / 24 MPa (low side) MPa"External Control"Diameter 99 - 103 mm"Length 200 - 220 mm"Weight < 5 kg with pulleyNew Developments92009200Max continuous speed (rpm)200 - 210213Length (mm)22Capacity – minimum (%)3329Displacement – cc (max)UnderDevel.CurrentModelSpecificationsCFD Modeling ResultsAriel view of a torturousseparatorInletOutletOil OutletOutletInletOil OutletContours of Oil ConcentrationPerformance Testing• Calorimeter testing and benchmarking• Testing carried out at 80, 100, 120, 140 bardischarge• Speed from 1000 – 8000 rpm to get entire range oftests• Control of pump• Speed ramp stability• Startup and shut down tests• Heat pump calorimeter testing• Compressor currently being tested at heat pumpconditions• Ambient temperatures as low as – 40 CTest mapStart up Characteristic@ 1000 RPM6.3 secShut down Characteristic@1000RPMTorque min 1.65 sec500 data points per secSummary• CO2compressor provides small package with highefficiency through lower pressure ratio vs. R134a• New materials will be needed to demonstrate durabilityat higher temperature and pressures associated withCO2• Fleet testing to validate component, system and controldesignThank you for listening !