Component Devel

for

JOERN FROEHLING / MARION LORE

FRED SCHROEDER / VIPEN KH

SRINIVAS PITLA
Fluid Transpo

Pressur

Dev

Fitting Te

Flexible 

Service P

Fluid 

Transport
CO2 – Design Crite

• Burst Re

- High s- Low s

• Materials

• Alumi• Stainl

• Sealing T

• < 1g C

• Max. Operating 

Temperatures

– High side: 180oC – Low side: 120oC

• Ambient conditions

-40 ... 120oC

• Pressure Relief Settings

- 16 MPa – High Side- 12 MPa – Low Side
Test duration 60 sec, Prototypes: 90 sec > 

Pressure [MPa] 4 < 

1

2

3

Temperature ambient

< 

0,2 g CO2/y (based on He- 

measurement)

RequirementLeakage

He-leakage test

Leakage and Permeat
CO2 - Visteon 

Service Port & C

Material of stem: Al or SS• Metal seal• Torx drive (uncommon)• Serviceable 

– SS housing: 250 re-assemblies with – Aluminum housing: >30 re-assembli

• Leak rate (SS)

– < 0.3 g/y @ 7% duty cycle (without c

• Sealing cap or dust cap • Safety ring – prevents projectile
He-Leakage 

Vibration 5 Hz,+/-15mm, -40...120°C Contamination Torque tolerances Pressure cycling 5...15 MPa, 225000 cycles, 180°CCO 

2-Permeation 

Housing S

Phase 2 design in development:• Outer surface will be in line with new SAE require

CO2 - Visteon Servic
CO2 - Service Cou

" 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 
SS, SS/Al 

(Al under development)

Material

Remarks • Serviceable (requires seal 

Installation Torque 25 Nm 

< 0.4 g/y @ 

7% duty cycle

Leak Rate (SS) Sealer material Metal 

Flare fitting 

Fittings
Peanut fitting –

Repeat Assembly T

• Blocks in Al• Different sealers• Sealers were changed after chang

Repeat Assembly Test 

Peanut E34

0,00,20,40,60,81,0

0123456

Amount of Repeat Assemblies

R744-Leakage [g/y] based on 

He -measurement

6Nm8Nm10Nm12Nm

0,00,20,40,60,81,01,21,41,61,82,02,22,4

01

R744-Leakage [g/y] based on 

He-Measurements
>200 h, 31 Hz,+/- 1

90°(no torsion)

Vibration

180° angleHP: 180°C, 0.5.. 15LP: 120°C, 0,2...12

Pressure cycling durability

+/- 15 ...20 mm, 5 -40°C...120°C (in the future: max. for HP-side)

Torsion durability

at 20°C/180°C

Test RequiremenBurst

Hoses Evaluation 
Flexibility tbd

Test in the CO2 NVH, 180° -system test r

HP: < 0,2 MPa, LP: < 

Requirement

Pressure dropTest

Hoses Evaluatio

CO2 Steelhose Whistle

Example at 1500 compressor rpm

-100

-80-60-40-20

0

20406080

100

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Frequency [Hz]

Acceleration [m/s2]

020406080100120140160180200

Sound Pressure Level

[dBA]

HP hoseLP hoseMicro

Pre

on th

0.000.200.400.600.801.00

100 15

Pressure drop [MPa] 
CO2-system - Char

• 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 R134a

- Charge - Evacuation- Release- Pressure test with N2 

HP
Variable Displace

Compressor For 

VIPEN KHETARPA

SRINIVAS PITLA
Introduction

" Clutch/Clutchless compresso" Design Burst Pressure: 34 M

side) / 24 MPa (low side) MPa

" External Control" Diameter 99 - 103 mm" Length 200 - 220 mm" Weight < 5 kg with pulley
New Developme

Max continuous speed (rpm) 920Length (mm) 21Capacity – minimum (%)

2

Displacement – cc (max) 29 

Curr

Mod

Specifications
CFD Modeling Re

Ariel view of a torturous 

separator

Inlet

Outlet

Contours of Oil C
Performance Te

• Calorimeter testing and bench

• Testing carried out at 80, 100, 1

discharge

• Speed from 1000 – 8000 rpm to 

tests

• Control of pump

• Speed ramp stability• Startup and shut down tests

• Heat pump calorimeter testing

• Compressor currently being test

conditions

• Ambient temperatures as low as 
Test map
Start up Characte

@ 1000 RPM

6.3 sec
Shut down Charac

@1000RPM

Torque min 1.6

500 data points per sec
Summary

• CO2 compressor provides small pack

efficiency through lower pressure ratio 

• New materials will be needed to demo

at higher temperature and pressures CO2

• Fleet testing to validate component, s

design
Thank you for lis