Evelopment of car air-conditioning test RIG using an electrical compressor

Anuar, Muhammad Ammar (2025) Evelopment of car air-conditioning test RIG using an electrical compressor. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Test rigs in educational settings have been proven to enhance learning by providing hands-on experience, improving comprehension of complex concepts, and fostering practical skills among students. However, it still lack of studies that covered topic about various types of compressor in automotive HVAC systems. Herein, this research aims to develop a Car Air-Conditioning Electrical Compressor Test Rig (CAECT) to evaluate the performance of system under various operational conditions for laboratory learning. Second objective is to study the relationship of refrigerant condition with different RPM affecting vibration level and temperature on alternative test rig. The development process followed the DoE approach included structural design, integration of monitoring equipment, validation through leak and also functionality testing. Online vibration monitoring was conducted using real-time data acquisition tools to record vibration level. Results shows that the developed test rig achieved a Coefficient of Performance (COP) of 5 and a maximum cooling temperature of 8°C, demonstrating its efficiency for laboratory learning. Meanwhile, data analysis revealed that RPM is the most influential parameter on vibration, with higher RPMs (1000, 1300, 1600, and 1900) increasing the vibrations and compressor temperatures, although it does not affect cooling temperature. Additionally, refrigerant levels significantly impact both cooling and compressor temperatures. The optimal refrigerant level of 320g achieved an 8°C cooling temperature and a minimal compressor temperature of only 39°C in idle RPM. However, refrigerant levels had an inconsistent effect on vibration, leading to fluctuations based on the applied quantity. These development and findings demonstrates the test rig is essential for laboratory learning and for future improvement in automotive and HVAC industry.

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