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Vehicle Cooling Load Calculation (Part I)

Vehicle cooling load calculation is important to efficiently design air conditioning systems. The cooling load is the amount of heat that must be removed to maintain the indoor temperature. It is calculated based on peak outdoor conditions and many factors, including metabolic heat from passengers, solar radiation, ambient temperature, engine heat, and more. Formulas are provided to calculate the individual load components from various surfaces and conditions, which are then summed to obtain the total cooling load. The goal is to accurately determine the air conditioning capacity needed.

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Saurabh Bhor
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
311 views

Vehicle Cooling Load Calculation (Part I)

Vehicle cooling load calculation is important to efficiently design air conditioning systems. The cooling load is the amount of heat that must be removed to maintain the indoor temperature. It is calculated based on peak outdoor conditions and many factors, including metabolic heat from passengers, solar radiation, ambient temperature, engine heat, and more. Formulas are provided to calculate the individual load components from various surfaces and conditions, which are then summed to obtain the total cooling load. The goal is to accurately determine the air conditioning capacity needed.

Uploaded by

Saurabh Bhor
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Vehicle Cooling Load Calculation-I

(4 Wheeler)

Sourav Kumar Patel


(CFD Engineer)

1
Concept

Concept of Cooling Load??


1. The design cooling load is the amount of heat energy to be removed to maintain the room at indoor design temperature.
2. The cooling load calculation is based on peak or near-peak conditions.(Extreme hot weather condition)
3. The goal is to create or build a structure with maximum efficiency to reduce the cost with cooling.
4. Cooling load calculation should be conducted before designing the air conditioning system.
5. The cooling system is one of the important systems, because it is related to passenger comfort.

2
Heat Load Types
𝑴𝒆𝒕𝒂𝒃𝒐𝒍𝒊𝒄 𝑳𝒐𝒂𝒅 𝑸𝑴𝒆𝒕
𝑫𝒊𝒓𝒆𝒄𝒕 𝑳𝒐𝒂𝒅 𝑸𝑫𝒊𝒓

𝑺𝒐𝒍𝒂𝒓 𝑳𝒐𝒂𝒅 (𝑸𝑺𝒐𝒍𝒂𝒓 )


𝑫𝒊𝒇𝒇𝒖𝒔𝒊𝒐𝒏 𝑳𝒐𝒂𝒅 𝑸𝑫𝒊𝒇

𝑹𝒆𝒇𝒍𝒆𝒄𝒕𝒆𝒅 𝑳𝒐𝒂𝒅 𝑸𝑹𝒆𝒇


𝐀𝐦𝐛𝐢𝐞𝐧𝐭 𝐋𝐨𝐚𝐝 𝑸𝑨𝒎𝒃

𝑻𝒐𝒕𝒂𝒍 𝑯𝒆𝒂𝒕 𝑳𝒐𝒂𝒅 (𝑸𝑻𝒐𝒕 ) 𝑬𝒙𝒉𝒂𝒖𝒔𝒕 𝑳𝒐𝒂𝒅 𝑸𝑬𝒙𝒉

𝑬𝒏𝒈𝒊𝒏𝒆 𝑳𝒐𝒂𝒅 𝑸𝑬𝒏𝒈

𝑽𝒆𝒏𝒕𝒊𝒍𝒂𝒕𝒊𝒐𝒏 𝑳𝒐𝒂𝒅 𝑸𝑽𝒆𝒏

𝑩𝒍𝒐𝒘𝒆𝒓 𝑳𝒐𝒂𝒅 𝑸𝑩𝒍𝒐𝒘𝒆𝒓

𝑨𝑪 𝑳𝒐𝒂𝒅 𝑸𝑨𝑪

𝑸𝑻𝒐𝒕 = 𝑸𝑴𝒆𝒕 + 𝑸𝑫𝒊𝒓 + 𝑸𝑫𝒊𝒇 + 𝑸𝑹𝒆𝒇 + 𝑸𝑨𝒎𝒃 + 𝑸𝑬𝒙𝒉 + 𝑸𝑬𝒏𝒈 + 𝑸𝑽𝒆𝒏 + 𝑸𝑩𝒍𝒐𝒘𝒆𝒓 + 𝑸𝑨𝑪

𝐴𝑡 𝑆𝑡𝑒𝑎𝑑𝑦 𝑆𝑡𝑎𝑡𝑒,
• 𝑸𝑻𝒐𝒕 = 𝟎
• 𝑸𝑨𝑪 = −(𝑸𝑴𝒆𝒕 + 𝑸𝑫𝒊𝒓 + 𝑸𝑫𝒊𝒇 + 𝑸𝑹𝒆𝒇 + 𝑸𝑨𝒎𝒃 + 𝑸𝑬𝒙𝒉 + 𝑸𝑬𝒏𝒈 + 𝑸𝑽𝒆𝒏 + 𝑸𝑩𝒍𝒐𝒘𝒆𝒓)
Note:
• Main objective is to calculate AC Load (Cooling Load).
• Ventilation load is due to ambient air leaking to cabin.
• Blower load is due to HVAC blower installed inside the cabin. 3
Heat Load Calculation (Formulas)

𝟏) 𝐌𝐞𝐭𝐚𝐛𝐨𝐥𝐢𝐜 𝐋𝐨𝐚𝐝 𝑸𝑴𝒆𝒕 = ෍ (𝑀 ∗ 𝐴 𝑏𝑠 ) 𝑊ℎ𝑒𝑟𝑒,


𝑝𝑎𝑠𝑠𝑒𝑛𝑔𝑒𝑟𝑠 • 𝑴 = 𝑀𝑒𝑡𝑎𝑏𝑜𝑙𝑖𝑐 𝐻𝑒𝑎𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒(𝑊 Τ𝑚2 )
𝟐) 𝐃𝐢𝐫𝐞𝐜𝐭 𝐋𝐨𝐚𝐝 𝑸𝑫𝒊𝒓 = ෍ (𝐴 𝑠 ∗ 𝜏 ∗ 𝐼𝐷𝑖𝑟 ∗ 𝐶𝑂𝑆𝜃) • 𝑾 = 𝑃𝑎𝑠𝑠𝑒𝑛𝑔𝑒𝑟 𝑤𝑖𝑑𝑡ℎ(𝑚)
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 • 𝑯 = 𝑃𝑎𝑠𝑠𝑒𝑛𝑔𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡(𝑚)
𝟑) 𝐃𝐢𝐟𝐟𝐮𝐬𝐢𝐨𝐧 𝐋𝐨𝐚𝐝 𝑸𝑫𝒊𝒇 = ෍ (𝐴 𝑠 ∗ 𝜏 ∗ 𝐼𝐷𝑖𝑓 ) • 𝑼𝒔 = 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝐻𝑇𝐶 𝑑𝑢𝑒 𝑡𝑜 𝑎𝑚𝑏𝑖𝑒𝑛𝑡 𝑙𝑜𝑎𝑑 (𝑊 Τ𝑚2 𝐾)
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 • 𝑼𝑬𝒙𝒉 = 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝐻𝑇𝐶 𝑑𝑢𝑒 𝑡𝑜 𝑒𝑥ℎ𝑎𝑢𝑠𝑡 𝑡𝑒𝑚𝑝 (𝑊 Τ𝑚2 𝐾)
𝟒) 𝐑𝐞𝐟𝐥𝐞𝐜𝐭𝐞𝐝 𝐋𝐨𝐚𝐝 𝑸𝑹𝒆𝒇 = ෍ (𝐴 𝑠 ∗ 𝜏 ∗ 𝐼𝑅𝑒𝑓 ) • 𝑼𝑬𝒏𝒈 = 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝐻𝑇𝐶 𝑑𝑢𝑒 𝑡𝑜 𝑒𝑛𝑔𝑖𝑛𝑒 𝑡𝑒𝑚𝑝 (𝑊 Τ𝑚2 𝐾)
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 • 𝑨𝒔 = 𝑆𝑢𝑟𝑎𝑓𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠ℎ𝑒𝑒𝑡 𝑚𝑒𝑡𝑎𝑙 𝑜𝑟 𝑔𝑙𝑎𝑠𝑠 𝑚2
𝟓) 𝐀𝐦𝐛𝐢𝐞𝐧𝐭 𝐋𝐨𝐚𝐝 𝑸𝑨𝒎𝒃 = ෍ { 𝑈𝑠 ∗ 𝐴 𝑠 ∗ 𝑇𝑠 − 𝑇𝑖 } • 𝑨𝑬𝒙𝒉 = 𝑆𝑢𝑟𝑎𝑓𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠ℎ𝑒𝑒𝑡 𝑚𝑒𝑡𝑎𝑙 𝑒𝑥𝑝𝑜𝑠𝑒𝑑 𝑡𝑜 𝑒𝑥ℎ𝑎𝑢𝑠𝑡 𝑝𝑖𝑝𝑒 𝑡𝑒𝑚𝑝 𝑚2
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 • 𝑨𝑬𝒏𝒈 = 𝑆𝑢𝑟𝑎𝑓𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠ℎ𝑒𝑒𝑡 𝑚𝑒𝑡𝑎𝑙 𝑒𝑥𝑝𝑜𝑠𝑒𝑑 𝑡𝑜 𝑒𝑛𝑔𝑖𝑛𝑒 𝑡𝑒𝑚𝑝 𝑚2
• 𝝉 = 𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑠𝑠𝑖𝑣𝑖𝑡𝑦 𝑜𝑓 𝑔𝑙𝑎𝑠𝑠 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠
𝟔) 𝐄𝐱𝐡𝐚𝐮𝐬𝐭 𝐋𝐨𝐚𝐝 𝑸𝑬𝒙𝒉 = 𝑈𝐸𝑥ℎ ∗ 𝐴 𝐸𝑥ℎ ∗ 𝑇𝐸𝑥ℎ − 𝑇𝑖 • 𝑨, 𝑩&𝑪 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡𝑠 𝑓𝑜𝑢𝑛𝑑 𝑓𝑟𝑜𝑚 𝐴𝑆𝐻𝑅𝐴𝐸 𝐻𝑛𝑑𝑏𝑜𝑜𝑘(𝑇𝑎𝑏𝑙𝑒 3.6)
• 𝜷 = 𝐴𝑙𝑡𝑖𝑡𝑢𝑒𝑑𝑒 𝑎𝑛𝑔𝑙𝑒 𝑡ℎ𝑎𝑡 𝑖𝑠 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑡𝑖𝑚𝑒 𝑑𝑒𝑔
𝟕) 𝐄𝐧𝐠𝐢𝐧𝐞 𝐋𝐨𝐚𝐝 𝑸𝑬𝒏𝒈 = 𝑈𝐸𝑛𝑔 ∗ 𝐴 𝐸𝑛𝑔 ∗ 𝑇𝐸𝑛𝑔 − 𝑇𝑖 • 𝜽 = 𝐴𝑛𝑔𝑙𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑛𝑜𝑟𝑚𝑎𝑙 𝑎𝑛𝑑 𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑢𝑛 𝑖𝑛 𝑠𝑘𝑦 𝑑𝑒𝑔
• 𝑪 = 𝐶𝑜𝑛𝑠𝑡 𝑓𝑟𝑜𝑚 ℎ𝑎𝑛𝑑𝑏𝑜𝑜𝑘
𝟖) 𝐕𝐞𝐧𝐭𝐢𝐥𝐚𝐭𝐢𝐨𝐧 𝐋𝐨𝐚𝐝 𝑸𝑽𝒆𝒏 = 𝑚𝑣𝑒 ∗ 𝑒𝑜 − 𝑒𝑖 • 𝜺 = 𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑡𝑖𝑙𝑡 𝑎𝑛𝑔𝑙𝑒 𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑑𝑒𝑔
• 𝒉𝒊 = 𝐼𝑛𝑠𝑖𝑑𝑒 𝑐𝑎𝑏𝑖𝑛 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑠𝑛𝑠𝑓𝑒𝑟 𝑐𝑜 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 (𝑊 Τ𝑚2 𝐾)
𝟗) 𝐁𝐥𝐨𝐰𝐞𝐫 𝐋𝐨𝐚𝐝 𝑸𝑩𝒍𝒐𝒘𝒆𝒓 = Blower Wattage ∗ Load factor/Efficiency • 𝒌 = 𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑠ℎ𝑒𝑒𝑡 𝑚𝑒𝑡𝑎𝑙 𝑜𝑟 𝑔𝑙𝑎𝑠𝑠
• 𝒕 = 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠ℎ𝑒𝑒𝑡 𝑚𝑒𝑡𝑎𝑙 𝑜𝑟 𝑔𝑙𝑎𝑠𝑠(𝑚)
𝑊ℎ𝑒𝑟𝑒, • 𝑻𝒔 = 𝑇𝑒𝑚𝑝 𝑜𝑓 𝑠ℎ𝑒𝑒𝑡 𝑚𝑒𝑡𝑎𝑙 𝑜𝑟 𝑔𝑙𝑎𝑠𝑠(deg 𝐶)
• 𝑨𝒃𝒔 = 𝐵𝑜𝑑𝑦 𝑆𝑢𝑟𝑎𝑓𝑐𝑒 𝐴𝑟𝑒𝑎 𝑚 2 = 𝟎. 𝟐𝟎𝟐𝑾𝟎.𝟒𝟐𝟓𝑯𝟎.𝟕𝟐𝟓 • 𝑻𝒊 = 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐶𝑎𝑏𝑖𝑛 𝑇𝑒𝑚𝑝 𝑑𝑒𝑔 𝐶
• 𝑰 𝑫𝒊𝒓 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝑆𝑜𝑙𝑎𝑟 𝐿𝑜𝑎𝑑(𝑊 Τ𝑚2 ) = 𝑨Τ𝒆𝒙𝒑(𝑩Τ𝒔𝒊𝒏(𝜷)) • 𝑻 = 𝐴𝑖𝑟 𝑇𝑒𝑚𝑝 (𝑑𝑒𝑔 𝐶)
• 𝑰 𝑫𝒊𝒇 = 𝐷𝑖𝑓𝑓𝑢𝑠𝑒 𝑆𝑜𝑙𝑎𝑟 𝐿𝑜𝑎𝑑(𝑊 Τ𝑚2 ) = 𝑪 ∗ 𝑰 𝑫𝒊𝒓 ∗ (𝟏 + 𝒄𝒐𝒔 𝜺 Τ𝟐) • 𝒎𝒗𝒆 = 𝑉𝑒𝑛𝑡𝑖𝑙𝑎𝑡𝑖𝑜𝑛 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝑘𝑔/𝑠)
• 𝑰 𝑹𝒆𝒇 = 𝑅𝑒𝑓𝑙𝑒𝑐𝑡𝑒𝑑 𝑆𝑜𝑙𝑎𝑟 𝐿𝑜𝑎𝑑(𝑊 Τ𝑚 2 ) = 𝑰 𝑫𝒊𝒓 + 𝑰 𝑫𝒊𝒇 ∗ 𝝆𝒈 ∗ (𝟏 + 𝒄𝒐𝒔 𝜺 Τ𝟐) • 𝒆𝒐 = 𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑎𝑚𝑏𝑖𝑒𝑛𝑡 𝑎𝑖𝑟
• 𝑼 = 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑐𝑜 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡(𝑊 Τ𝑚 2 𝐾) = 𝟏Τ𝑹 • 𝒆𝒊 = 𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑐𝑎𝑏𝑖𝑛 𝑎𝑖𝑟
• 𝑹 = 𝑁𝑒𝑡 𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑎𝑟𝑒𝑎 = 𝟏Τ𝒉𝒐 + 𝒕Τ𝒌 + 𝟏Τ𝒉𝒊 • 𝑵 = 𝑅𝑃𝑀 𝑜𝑓 𝑒𝑛𝑔𝑖𝑛𝑒
• 𝑻𝑬𝒙𝒉 = 𝑇𝑒𝑚𝑝 𝑜𝑓 𝐸𝑥ℎ𝑎𝑢𝑠𝑡 𝑔𝑎𝑠 𝑑𝑒𝑔 𝐶 = 𝟎. 𝟏𝟑𝟖 ∗ 𝑵 − 𝟏𝟕 • 𝝋 = 𝑅𝑒𝑙𝑎𝑡𝑖𝑣𝑒 ℎ𝑢𝑚𝑖𝑑𝑖𝑡𝑦
• 𝑻𝑬𝒏𝒈 = 𝑇𝑒𝑚𝑝 𝑜𝑓 𝐸𝑛𝑔𝑖𝑛𝑒 𝑑𝑒𝑔 𝐶 = −𝟐 ∗ 𝟏𝟎−𝟔 ∗ 𝑵𝟐 + 𝟎. 𝟎𝟑𝟓𝟓 ∗ 𝑵 + 𝟕𝟕. 𝟓 • 𝑷 = 𝐴𝑖𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑡 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇(𝑃𝑎)
• 𝑷𝒔 = 𝐴𝑖𝑟 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑎𝑡 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇 (𝑃𝑎)
• 𝒆 = 𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑎𝑖𝑟 = 𝟏𝟎𝟎𝟔 ∗ 𝑻 + 𝟐.𝟓𝟎𝟏 ∗ 𝟏𝟎𝟔 + 𝟏𝟕𝟕𝟎 ∗ 𝑻 ∗ 𝑿 • 𝝆𝒈 = 𝐺𝑟𝑜𝑢𝑛𝑑 𝑟𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
• 𝑿 = 𝐻𝑢𝑚𝑖𝑑𝑖𝑡𝑦 𝑅𝑎𝑡𝑖𝑜 𝑖𝑛 𝑔𝑟𝑎𝑚 𝑜𝑓 𝑑𝑟𝑦 𝑎𝑖𝑟 = 𝟎. 𝟔𝟐𝟏𝟗𝟖 ∗ 𝝋𝑷𝒔Τ𝟏𝟎𝟎𝑷 − 𝝋𝑷𝒔 • 𝑽 = 𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑉𝑒ℎ𝑖𝑐𝑙𝑒 ( 𝑚Τ𝑠)
• 𝒉𝒐 = 𝑂𝑢𝑡𝑠𝑖𝑑𝑒 𝑎𝑚𝑏𝑖𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑠𝑛𝑠𝑓𝑒𝑟 𝑐𝑜 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 𝟎. 𝟔 + 𝟔. 𝟔𝟒 ∗ 𝑽

Note:
• Ambient load is calculated for sheet metal and glass surfaces.
• Solar Load is calculated for glass surfaces only. 4
References:
• Cooling Load Calculation and Thermal Modeling for Vehicle by MATLAB (Oum Saad Abdulsalam1, Budi Santoso2, Dwi Aries).
• Handbook of Air conditioning and Refrigeration

5
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