How Does Automotive Electric Air Conditioning System Manufacturer Work?

The engine in an electric car does not generate heat, so EVs must use specially designed heating and cooling systems. Maintaining the right temperature in the cabin in winter is not only a matter of driving comfort, but above all safety, since the windows must not be fogged up or frosted. You should know how an air conditioning system works in order to use it optimally. 

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The principle of air conditioning in the car 

The air conditioning system works in conjunction with the car's heating system and is responsible not only for cooling the interior in summer, but also for warm air in winter. The common element of both systems is the refrigerant, which, depending on the mode of operation, receives heat from the heater or is cooled in the radiator. Circulation of the refrigerant at as high pressure as 17 bar is forced by a compressor driven by a multi-ribbed belt, which in turn transmits the drive from a pulley on the engine's crankshaft. In the cooling system, the refrigerant enters a condenser cooled by a momentum of air or a fan and changes from a gaseous to a liquid state. From there, the liquid is transported to a dehumidifier and then an expansion valve, where it transforms into a -4 °C gas. It then cools the evaporator, through which the air blown into the cabin flows. In a heating mode, on the other hand, the same refrigerant takes heat from the engine and transfers it to the heater, which heats the air flowing through it. An engine-driven fan is responsible for blowing cooled or heated air into the cabin. Knowing how air conditioning works in a combustion car, it is easier to understand the principle of this system in electric cars. 

Air conditioning system in an electric car ' what is the difference? 

The electric motor does not emit heat, but this does not mean there is no heating in the car. The mechanism of operation of cooling and heating systems in electric cars is actually not very different from those found in combustion cars. The main difference is the power source of the compressor. It is not the crankshaft in this case, but the batteries for electric cars. Compressors in EVs have their own built-in electric motor, an inverter that converts direct current drawn from the battery into AC, and a separator that separates the compressor oil from the refrigerant. Among the advantages of the solution, where the compressor is powered directly from the battery, is the ability to run the air conditioner while parked, with the engine off. In new electric cars you can also find a heating system based on a heat pump, which somewhat resembles the split air conditioners used to heat buildings. The air-to-air heat pump can operate in both heating and cooling modes. In a heating mode, the warm air it produces is directly blown into the cabin, while in cooling mode it goes to a condenser, followed by a dehumidifier, expansion valve and evaporator. The heat pump is also powered by a lithium-ion battery using an inverter. 

How to heat the interior of an electric car? 

Turning on the car's heating increases the energy demand for the compressor, which in the case of electric cars is associated with faster battery drainage. Given the small number of fast chargers and the extended battery charging time in cold weather, BEVs seem like a good option only for city trips, and that's provided you have your own charging point at home. However, there are ways to reduce the electricity consumption of electric vehicles and hybrid cars in winter. First, preheat the car's interior even before hitting the road. It's best to plug it into a charger, or if that's not possible, set it up in a sunny location. Secondly, while driving, it is a good idea to turn on the economy mode that reduces the energy consumption of individual systems to a minimum. If the car is equipped with heated seats and steering wheel, you can set the interior temperature to the lowest level or opt for no heating in the car. However, energy consumption for heating the interior depends not only on skillful energy management, driving speed and battery operating temperature, but also on the type of heating and proper insulation of the car's interior. 

The use of fan heaters 

There are several different types of heating in electric cars, but the most common is an electric heater connected to a blower. Although the power of such heaters is mostly small, as low as 2 to 4 kW, in negative temperatures they greatly accelerate the process of battery drainage. It has even been tested in practice how long an electric car battery lasts in winter. Tests conducted by the American Automotive Association showed that in temperature conditions below -7°C, the average range of an electric car drops by up to half compared to optimal conditions of 24°C. This problem does not occur in warm climatic conditions, but in northern Europe or America, for example, where there are sometimes very harsh winters, the use of such heating in the car can make it impossible to travel long distances outside the city. 

Advantages and disadvantages of a heat pump in the car 

Heat pump is an increasingly common type of heating in electric cars. By properly compressing and expanding the heating medium, free heat energy drawn from outside can be used to heat the vehicle cabin. Tests in winter conditions have shown that this requires less energy than a traditional system with an electric heater, but only within a certain range of outdoor temperatures. At temperatures between 0 and 10°C, the heat pump is estimated to consume about 1 kW of energy, so it saves 1-2 kW for every hour of operation. At lower temperatures, the situation changes to the disadvantage of the heat pump. It is also often emphasized that the heat pump is a good solution only if the car is used for city driving and has a battery with a relatively small capacity. If the car is to cover longer distances, it is more profitable to invest in a model with a more capacious battery and a system based on a traditional resistance heater. 

High Voltage Heater ' what is it and how does it work? 

The High Voltage Heater (HVH) is a device that is small in size and weighs just 2.7 kilograms, yet is very efficient. Unlike heat pumps, this technology is based on a water heating model instead of air heating. It can be used for both maintaining a comfortable temperature in the cabin and preheating or cooling the traction engine. The HVH heater is designed to operate over a wide range of supply voltages from 100 to 450 V, while its maximum heating power is as high as 7 kW. The high efficiency of this solution makes it applicable to large vehicles, such as trucks and buses. The most common application of this technology is electric parking heating of the driver's cabin used in trucks, but it is also successfully used in passenger cars. Automobile design is increasingly combining all of these technologies in various combinations, or using the most comprehensive solutions possible to provide the greatest benefits. 

Insulating materials and the range of an electric car 

A very important aspect from the point of view of maintaining a comfortable temperature in the vehicle cabin is not only to produce heat or cold efficiently, but also to retain it where it is needed. In this regard, automotive components made of EPP foamed polypropylene, which features excellent thermal insulation, impact and deformation resistance, and minimal weight, are perfectly applicable. Even today, EPP has become a leading material that is widely used by car seat manufacturers. Among other things, it is used to manufacture seat fillings, headrests, armrests or car door panels, and even body components for passive safety. The excellent moldability and electrical properties of this material have also led to its use in the production of batteries for electric cars. Battery components molded from it protect sensitive cells from extreme temperatures, surges and mechanical damage. Thus, they make it possible to increase the range and safety of electric cars in many ways. 

Electric vehicles address environmental concerns and are revolutionising the driving experience. In this article, we will answer a couple of questions:

How does an air conditioner work? How to integrate air conditioning systems in the electric car?

This article will delve into heating, ventilating and air conditioning in electric cars, highlighting the importance of combining the different energy efficiency targets, vehicle range, and overall driving comfort.

We will explore the various components and technologies, emphasising their impact on electric car performance and the environment. We will also explore the role of AI in product design for these components.

But before delving to AI and advanced engineering simulation, two frequently asked questions to tackle are:

1. Is air conditioning really an essential component?
2. and, how does a car's air conditioning system (cooling or heating system) work?

Read below to get the answers.

Why Having an Air Conditioning System Is Essential

An automotive air conditioning system is also crucial to your car's interior, especially during the hot and cold seasons. It maintains a controlled temperature and humidity level, ensuring your comfort as a passenger. Unlike standard air, it filters out pollutants and allergens, providing relief during extreme weather conditions. It also prevents condensation on windows, enhancing driving safety in all seasons and weather conditions. If you want to understand how an automotive air conditioning system works, it utilizes the principles of thermodynamics. This system circulates a refrigerant that absorbs heat from the passenger compartment and releases it outside. This process creates a cooling effect distributed through the car's vents. An automotive air conditioning system is essential to provide comfort, safety, and better driving experiences. So, please keep it in good condition to enjoy its benefits all year round!

How an Automotive Air Conditioning System Works

Automotive air conditioning works based on the principles of thermodynamics, utilising the refrigeration cycle to transfer heat and regulate humidity.

AC Compressor and Condenser

The cycle commences with the AC compressor, a mechanical pump powered by the vehicle's engine. This component compresses a low-pressure, low-temperature gaseous refrigerant, causing its temperature and pressure to rise significantly. The high-pressure, high-temperature refrigerant vapour then flows into the condenser, a heat exchanger at the front of the vehicle's cabin. As ambient air passes over the condenser coils, the refrigerant releases heat and undergoes a phase transition, transforming into a high-pressure liquid.

Expansion Valve and Evaporator

Subsequently, the high-pressure liquid refrigerant passes through the expansion valve, which experiences a rapid pressure drop. This reduction in pressure causes the refrigerant to expand, leading to a substantial decrease in temperature as it enters the evaporator.

The evaporator within the cabin facilitates heat exchange between the refrigerant and the warmer cabin air. The refrigerant absorbs heat from the air, causing it to evaporate and return cool air to a low-pressure gas state.

Blower Fan and Cabin

The blower fan then circulates the cooled air across the evaporator coils, reducing the cabin temperature and lowering humidity levels as moisture condenses on the evaporator's surface. This cooled, dehumidified air is directed into the cabin, providing occupants a comfortable environment even in hot and humid conditions.

AC and heating Systems

In a conventional air conditioning system, components like a heat pump or an electric heater play crucial roles in maintaining optimal temperatures. These elements ensure efficient heating and cooling, contributing to overall comfort and energy efficiency.

The Evolution of Air Conditioning in Electric Cars

Electric vehicles have evolved from a niche concept to a mainstream automotive choice. With advancements in battery technology as an energy storage system, electric vehicles have become more accessible, efficient, and practical for everyday use. However, integrating air conditioning systems in the electric car posed unique challenges due to the less energy-intensive nature of traditional air conditioning units.

Engineers had to innovate and develop new technologies to ensure that air conditioning systems in electric cars met consumer expectations and aligned with the sustainability goals of the electric vehicles revolution with an electric motor replacing traditional internal combustion engine vehicles.

Air Conditioning System Components and Their Functions

Modern air conditioning systems in electric cars combine new technology with the design of components for effective cooling and heating while minimising energy consumption.

Let's go into detail about some of the air conditioner's key components and functions now!

The Electric Comprheatingessor

The heart of the air conditioning system in an electric can, the electric compressor, is responsible for circulating the refrigerant and enabling the cooling process. Unlike traditional internal combustion engine (ICE) vehicles, where the engine's crankshaft drives the compressor, electric cars have an independent electric motor that extracts power from the vehicle's battery.

A central element comes into focus: the electric compressor. In this section, we give more details about this component, shedding light on its mechanics and its impact on the efficiency and performance of electric cars.

A Core Component for the Air Conditioning System

The compressor is at the centre of every air conditioning system, responsible for circulating refrigerant and initiating the cooling process. In conventional internal combustion engine (ICE) vehicles, this critical component is often linked to the engine's crankshaft, drawing power from the engine. However, a different scenario unfolds within electric vehicles.

Independence and Power

Unlike traditional vehicles with internal combustion engines, electric vehicles are equipped with independent electric compressors that operate separately with their electric motor from the vehicle's propulsion system.

This independence arises from the high-capacity battery's unique power source in electric vehicles. The electric compressor directly draws power from the battery, allowing for independent operation without impacting the vehicle's primary drive system.

Efficiency

The transition to independent electric compressors has implications beyond novelty; it forms the basis of improved energy efficiency.

By separating the ventilation and air conditioning system from the engine's mechanical processes, electric vehicles can ensure that the cooling or heating demands do not compromise the vehicle's range or overall performance. This efficiency highlights the adaptability and versatility of electric drivetrains.

Addressing Energy Efficiency Concerns

A primary concern in vehicle electrification is efficiently using stored battery energy for power. Electric compressors offer an effective solution by harnessing the battery's energy to maintain cabin temperatures. The result is a balance between comfort and performance, demonstrating the integration of advanced technology and sustainable transportation objectives.

A Look Ahead

As electric vehicle technology advances, electric compressors in ac and heating systems will likely undergo further refinements. Anticipated innovations may include more advanced power management algorithms, improved thermal control mechanisms, and tighter integration with other vehicle systems.

Leading Corporations at the Forefront

Regarding air conditioning, Tesla employs a compressor reminiscent of those found in a household refrigerator, albeit tailored for 400 V voltage. Positioned at the car's frontal section, this compressor draws its energy straight from the vehicle's energy storage system at the rear. This ingenious setup chills the air before it finds its way to the AC vent. The heating mechanism departs from the conventional approach seen in traditional vehicles. Instead, an electric heater sources its power from the same energy storage system, adding another layer of innovation to Tesla's design.

For more information, please visit Automotive Electric Air Conditioning System Manufacturer.

Another notable electric car player, BMW, has harnessed the power of electric compressors to redefine cabin comfort in its electric vehicle lineup. Prioritising intelligent thermal management, electric compressors on BMW EVs maintain consistent and energy-efficient climate control.

Battery Power Source for the AC System

The air conditioning system draws power from the vehicle's battery pack to operate the compressor, fans, and other components. Efficient use of the car's battery pack for power is essential to minimise energy consumption and optimise the vehicle or car's range. The remaining AC system technologies do not greatly differ between traditional cars and EVs.

Heat Pump Technology

Many electric cars utilise heat pump technology to heat or cool the cabin efficiently. Heat pumps transfer heat between the inside and outside of the vehicle, making them far more energy-efficient than conventional resistance-based heating systems.

Expansion Valve

The expansion valve is a critical component that controls the refrigerant flow, facilitating the cooling process. It regulates the pressure and temperature of the refrigerant as it moves through the system.

Impact of Experimental Testing and CFD Simulation

Proper ventilation and airflow management ensure uniform cooled or heated air distribution throughout the cabin. Advanced systems use sensors and actuators to adjust airflow and temperature settings based on occupant preferences.

Precision and Uniformity Through Ventilation

Adequate ventilation forms the backbone of a comfortable and refreshing cabin environment. Airflow patterns promoting even cooled or heated air distribution are crucial to preventing localised discomfort and enhancing passenger well-being. To achieve this, modern vehicles combine carefully designed ducts, vents, and fans that work in harmony.

Experimental measurements are crucial here, involving real-world testing to validate and fine-tune the airflow pathways. These measurements provide valuable insights into how air interacts with various cabin components, enabling engineers to refine the system for optimal engine performance throughout.

Sensors and Actuators

To deliver an exceptional in-cabin experience, automotive engineers employ a sophisticated array of sensors and actuators. These components act as the orchestra conductor, orchestrating the airflow to meet occupant preferences and environmental conditions. Temperature and humidity sensors monitor the cabin's internal conditions, providing real-time data that guides the system's response.

Actuators, in turn, adjust the position of vents and modulate fan speeds to maintain uniform comfort levels. This dynamic interplay between sensors and actuators ensures that the system adapts seamlessly to changes in external temperature, humidity, and passenger preferences.

The Role of Computational Fluid Dynamics (CFD)

As automotive engineering ventures into the digital thread, CFD simulations emerge as a critical tool in optimising ventilation and airflow management.

By starting from CAD virtual models of the cabin and its components, CFD enables engineers to predict and analyse airflow patterns, temperature distribution, and comfort levels under varying conditions.

These 3D precise simulations comprehensively understand how different design parameters influence cabin air movement, facilitating iterative refinements without requiring extensive physical prototypes.

The New Role of Deep Learning in AC System Design

Deep Learning for engineers provides a further exciting chapter in our story. By accumulating years and numerous terabytes of CAD and CFD data, judicious learning can be driven by cutting-edge technologies inspired by computer vision techniques.

Deep Learning (a branch of AI based on specialised neural networks) can now provide actionable, real-time surrogates of time-consuming CFD simulations. Air conditioner components such as the mixer or compressor can be simulated within fractions of seconds with Deep Learning, provided this is enough initial data to learn from.

Deep Learning can thus provide a new simulation technology for Heating, Ventilation and Air Conditioning (HVAC) or heat exchanger design in automotive engineering and other industries.

Impact on Energy Efficiency and Range

Integrating advanced air conditioning systems in electric cars impacts energy efficiency and vehicle range. Unlike traditional internal combustion engine vehicles, where the engine's power is diverted to drive the AC compressor, electric cars can power the compressor directly from the battery pack'this decoupling of the AC system from the engine results in several advantages.

Energy Efficiency

Electric cars with optimised AC systems can maintain a comfortable cabin temperature without significantly affecting the vehicle's overall energy consumption or battery life. Efficient heat pump technology and intelligent energy management contribute to this achievement.

Range Optimisation

Electric car manufacturers can extend the vehicle's range by using battery power judiciously and employing energy-efficient components. This is crucial in promoting electric car adoption, as potential buyers' range anxiety remains a concern.

Regenerative Braking Integration

Some innovative AC systems in electric cars integrate with regenerative braking technology. Excess heat generated during braking can heat the cabin or precondition the battery, enhancing energy efficiency.

Climate Control Customisation and Preconditioning

Advanced air conditioning systems allow occupants to customise climate control settings for different zones within the cabin. This ensures personalised comfort while minimising energy wastage.

EVs excel in pre-conditioning cabin air. Since they don't rely on the engine for heating or cooling, you can remotely pre-condition the cabin using the mobile app. This means you can heat or cool the cabin. At the same time, the vehicle is still plugged in, ensuring a comfortable interior temperature before you start driving without using energy from the battery while on the road.

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Enhancing Driving Comfort and Performance in the Electric Car

Air conditioning systems in an electric vehicle enhance energy efficiency and contribute to overall driving comfort and performance.

Below we are listing a few important factors.

Instant Heating and Cooling

Electric cars benefit from rapid cabin heating or hot air cooling due to the electric compressor's instantaneous response. This feature improves driver and passenger comfort, particularly in extreme weather conditions.

Independent Chilling Units

Some electric cars feature independent chilling units that allow users to precondition warm air in the cabin while the vehicle is still charging. This feature ensures a comfortable interior before starting a journey.

Heated Seats and Steering Wheels

Electric cars often include heated seats and steering wheels that provide localised warmth, reducing the need for extensive cabin heating. This feature is energy-efficient and enhances driver comfort.

Quiet Operations

Electric compressors produce less noise than traditional cars and their ICE counterparts, contributing to a quieter cabin environment, unlike traditional vehicles. This aligns with the overall goal of reducing noise pollution in urban areas.

Future Prospects for AC in the Electric Vehicle

The integration of advanced air conditioning systems in electric cars aligns with the broader environmental objectives of the electric car revolution. Traditional vehicles powered by internal combustion engines consume fossil fuels, releasing greenhouse gases and pollutants into the atmosphere. With their energy-efficient AC systems, electric cars reduce the carbon footprint and the menace to the environment associated with climate control in conventional vehicles.

Looking ahead, further advancements in battery technology delivering power, heat pump efficiency, and thermal management systems will continue to improve the performance of air conditioning systems in electric cars. AI-driven predictions will play an important role for product design engineers.

Conclusions

Technological innovation, environmental responsibility and occupant comfort! Those factors are driving conditioning systems in electric cars.

All the factors must be considered together! Thus, engineers can design energy-efficient and sustainable EVs without compromising on occupant well-being.

Advanced design methods such as CFD or Deep Learning are facilitating tools in this process. The automotive industry will thus likely witness further innovations, based on AI and generative design solutions at the service of automotive product design engineers.

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