Vehicle Air Conditioning

Dr. A. S. Dhoble
Functions of Vehicle AC system

•Air Conditioning is a
method of controlling the
heat.
•The control of
temperature means control
of comfort

Heat in either extreme,

extreme to much or
to little is Uncomfortable.

Heat in correct amount

will provide life and
comfort
 Heat
• All substances contain heat.
• Something "feels" hot when it is warmer than our body
temperature. When something contains less heat than our
bodies, we say it feels cold!
• Cold is merely the removal of some heat.
• Science tells us that a measurement called "Absolute Zero" is
the point at which all heat is removed from an object
(approximately -273⁰ C).
• Any substance above this absolute zero temperature retains
some heat.
 Sources of heat transfer in vehicle

• When a car is driven or parked in the sun, heat enters the vehicle
from many sources.
These sources include:
- Ambient air
- Sunlight
- Engine heat
- Road heat
- Transmission
- Exhaust heat
• All of these and other miscellaneous heat sources, increase the air
temperature within the vehicle.

• In a high ambient temperature situation, (e.g. on a 37⁰ C day), the

interior of a vehicle left standing in the sun with windows closed
could reach 65⁰ - 70⁰ C!
 Heat Entering the Vehicle

• Calculation of
Heat Load is
done based on
these sources of
heat.
• Total Heat load
of vehicle is
estimated.
• AC system is
designed for that
heat load.

Tons is often used as a general term to indicate the capacity or size of the refrigeration plant.

1 TR is defined as the rate of heat transfer that results in the freezing (*or melting) of 1 short
ton (907 kg) of pure ice at 0 °C (32 °F) in 24 hours.
 HVAC System

• Heating Ventilation and Air Conditioning System (HVAC)

• A HVAC System consists of a chain of components designed to
heat, ventilate or cool a specific area while maintaining a
defined environmental cleanliness level.
• Heating, ventilation, and air conditioning (HVAC) is the
technology of indoor and vehicular environmental comfort.
• Its goal is to provide thermal comfort and acceptable indoor
air quality.
 Ventilation

• Ventilating or ventilation (the V in HVAC) is the process of

exchanging or replacing air in any space to provide high indoor air
quality which involves temperature control, oxygen replenishment,
and removal of moisture, odours, smoke, heat, dust, airborne
bacteria, carbon dioxide, and other gases.

• Ventilation removes unpleasant smells and excessive moisture,

introduces outside air, keeps interior air circulating, and prevents
stagnation of the interior air.
 Expectation from AC System

• The system must be capable of keeping a temperature of 22˚C

inside a stationary black vehicle with four occupants, with an
outside temperature of 40˚C.

• Also, the system must be an efficient heating system, keeping

an internal temperature of 15˚C with an outside temperature
of 0˚C.
Refrigeration Cycle

Vapour Compression
Cycle

1-2 :Compression

2-3 : Condensation

3-4 : Expansion

4-1 : Evaporation
 General Layout of AC system

• The substance used in the air conditioning system is called refrigerant.

• It boils at different temperatures depending upon the pressure that it is under.
Typical Flow Diagram of Ac System
 Working of AC System
• The cooling begins with evaporator(small fin and tube heat exchanger)
located in passenger compartment. As low pressure liquid refrigerant
enters the evaporator, it absorbs the heat and vaporises. This cools the
surrounding area (Passenger Compartment)
• Accumulator traps moisture and prevent liquid refrigerant from entering
the compressor.
• The compressor takes in low pressure refrigerant vapour and pressurize to
high pressure so that temperature goes up.
• The hot and pressurised vapour are passed through condenser where it
gets condensed into liquid.
• The high pressure condensed liquid is passed through orifice tube which
reduces a pressure of liquid refrigerant flowing into evaporator.
• The above processes are repeated in cycle to achieve refrigeration effect.
 AC Compressor

• It is a pump driven by a belt attached to the

engine’s crankshaft.
• Puts the refrigerant gas under pressure and
forces it to the condenser.
• It cant compress liquids, only gases.
• By increasing the pressure the refrigerant gas
leaving the compressor becomes hot.
• Also called as heart of the air conditioning
system.
• Earlier freons(R-12) were used as refrigerants.
• Nowadays environment friendly HFC(R-134a) is
used as refrigerant.
 Condenser

• Identified as second radiator of the car that

shares air flow with main radiator.
• Has its own cooling fans that become active
when AC is on.
• Takes up the heat from the high pressure
refrigerant gas and cools it.
• Condensing of the refrigerant gas causes it to
loose heat and form into a liquid.
• Heat is expelled into the atmosphere by the air
flowing from the cooling fans.
Condenser Location
 Evaporator

• Radiator like device buried deep

under the dashboard.
• Refrigerant gas enters the evaporator
coils and absorbs the heat inside the
car’s cabin and moves out of the
coils.
• A fan blowing over the outside of the
evaporator coil blows cool air into the
passenger compartment.
• Thus the evaporator takes humidity
out of the air in the car, which helps
passengers feel cool
 Receiver or Dryer

• Small reservoir installed in the line

of the condenser.
• Main function is to remove
moisture and other contaminants
from the cool refrigerant liquid.
• Contains small granules called
desiccants that attract water.
• If water is not removed, it can form
ice crystals, thereby damaging the
whole system
 Expansion valve

• The pressure of refrigerant is reduced

causing expansion of the liquid,
resulting in further cooling.
• Slowly the liquid reverts back into a
gaseous form.
• Also the valve reduces pressure on the
refrigerant so it can easily move into
the evaporator.
• The valve senses pressure and
regulates the flow of refrigerant,
• which allows the system to operate
steadily
 General Comments
• An AC system not only cools the cabin, it removes dust and
dirt, leaving only with fresh air.
• One has to remember to use only environment friendly
refrigerants and avoid CFCs (Chlorofluorocarbons) as much as
possible. As CFCs destroy ozone layer.
• The AC system can be recharged by adding fresh refrigerant
and removing the remaining one.
• Care must be taken in the disposal of refrigerants as they may
affect the soil, rivers, etc.,
• Its also necessary to check the AC system for leaks as it may
lead to the loss of refrigerant as well as environmental
hazards.
 Future Systems

Now a days automobile HVAC system are under development

and have used atmospheric carbon dioxide ( CO2 ) as a
refrigerant which is compatible to R134a in performances and
efficiency. This system also has advantage to reduce carbon
emission which in turn results into reduce green house effect.
Also in newer cars a “computer control system” is used to
control multi-zone HVAC system which can give comfort to a
individual occupant as per the occupant required.
 Air Distribution System
• The air distribution system is used to direct filtered air flow into the
passenger compartment of a vehicle. This flow of air is controlled
by the use of flap doors.
• The temperature of the air flowing into the passenger
compartment is controlled by a combination of reheated air
through a heater core and outside air. Airflow through the heater
core is controlled by the temperature selector.
• A multi-speed fan is used to change the rate of airflow into the
passenger compartment.
• The driver can adjust the settings of the air distribution system by a
control panel (head) mounted in the instrument cluster.
 Typical Heater & A/C Assembly Layout
The heater and air conditioning distribution assembly is split into three sections:
Air inlet, plenum and air distribution.

Air Inlet Section Plenum Section Air Distribution Section

Filtered fresh air in Evaporator Air to defrost panels
Heater core

Floor
Intake door air out

Air mix
Recirculated air in (blend) door Air to panel outlets
The air inlet section contains the fresh air and recirculated air inlets. Note that
the fresh air inlet normally includes a filter to ensure that debris does not enter
the system.
The plenum section contains the evaporator, heater core and air mix (blend)
door, and the air distribution section contains the panel, defroster and floor
control doors.
 General Working of The System

The evaporator cools all air flowing through it and removes any moisture in
the air.
The heater core warms the air to a temperature determined by the driver. The
fan is used to move air into, through and out of the assembly.
The position of the control doors are set by the driver via the use of control
levers or knobs, so air flows into the vehicle as and where required
 Location Air Distribution System
• The heating and air conditioning
distribution assembly is typically
situated at the rear of the engine
compartment and fixed to the
bulkhead.
• The air distribution assembly is
typically made from reinforced plastic
or pressed steel sections.
• Air conditioning system hoses
are connected directly to the
evaporator in the assembly.
• Driver operated heater and air
conditioning controls are connected to
the assembly from the vehicle’s
interior via cables and/or
electrical connectors.
 Blend Air Reheat System

• In the blend-air reheat system

shown, recirculated and/or
outside air is firstly passed
through the evaporator to cool it
and remove any moisture.
• This cold air is then passed
through or around the heater
core, or both.
• The amount of air that passes to
the heater core is determined by
the position of the air blend
door, which is adjusted by driver
controls in the passenger
compartment.
 Temperature Control of Air
• When the driver’s temperature control is
set to its hottest position, all of the air
from the evaporator passes through the
heater core.
• When the driver’s temperature control is
set to its coldest position, all of the air
from the evaporator passes around the
outside of the heater core.
• When the driver’s temperature control is When the air conditioning
set between its hottest and coldest lever is set to NORM, outside
positions, some air passes through the air is drawn into the system
heater core, while the rest goes around it. and when in the MAX A/C
position, recirculated air is
The air then combines (blends) to produce drawn in. For both settings,
the required temperature in the passenger air is output to the defrost,
compartment floor and panel outlets.
Layout of Front and Rear Passenger Compartment Ducts

•The passenger compartment

ducts are typically made from
reinforced plastic. However,
some vehicles have sheet
metal or wire-reinforced
flexible ducts.

•Some vehicles only direct air

to the front passenger
compartment.

•The ducts must be designed

to be compact to fit confined
spaces, quiet in operation
and leak free.
 Save Environment!!
Use AC to the minimum extent
possible!!