FEATURE GEARS, GEARBOXES & POWER TRANSMISSION
Hybridisation is playing a key role in reducing CO2 emissions from all vehicle classes. Buses operating in hot/tropical environments, which
rely heavily on air conditioning, typically must keep vehicles cool even when at bus stops and depots. While it is well established that AC compressors represent a high parasitic load on the engine, the challenge
is in reducing this to yield significant CO2 reductions. David Latimer, CEO of Magnomatics, explains how MAGSPLIT technology can help
GETTING ON BOARD FOR THE FUTURE OF AUTOMOTIVE AIR CONDITIONING
over-performs at higher engine speeds and unnecessarily increases parasitic losses. This
A
is drawn into sharp focus by the European CO2 emission standard for EU trucks and buses which require a 15% and 30% reduction by 2025 and 2030 respectively. The fines for non-compliance imposed are significant (6,800 EUR per
gCO2/
Ton.km or 570 EUR per gCO2/km) and in the case of no improvement in CO2 from EURO6, fines will reach 27,234 EUR/(truck/bus). These
penalties are driving owner/operators to increase adoption of fuel reduction technologies. The net reduction in fuel consumption (CO2
production) for this class of vehicle has shown particularly poor performance in recent years (in a sample of 97 HGV/buses over the period 2002-2016, the average annual reduction was only 0.04% [Efficiency standards HDVs EU Briefing by ICCT]) and focus has moved to ‘peripheral’ technologies (rather than those
focused solely on engine CO2 emission), of which ancillary on-demand feature heavily.
MAGSPLIT BENEFITS Magnomatics’ MAGSPLIT allows a vehicle’s air conditioning compressor to operate independently from the speed of the engine. This means that potentially the air compressor can be downsized and run close to its optimal operating point for most of the time. It also enables engine off operation for stop/start vehicles. Internal analysis by Magnomatics has shown
that a MAGSPLIT controlled AC compressor can save up to 12% fuel, depending on vehicle type and usage cycle, when compared to the leading competitors (engine driven compressor or three high-power variable displacement units) for which the main (bus) market displacement is aimed. In this case the savings in terms of penalty avoidance is up to 22,000 EUR, and the fuel consumption saving is 4,400 litres/year which equates to an annual saving of 4,840
utomotive compressors currently need to maintain full power during engine idle phases, meaning the compressor
EUR/year (consistent with ICCT's briefing). Hence the customer is heavily incentivised to purchase. This financial benefit is compounded,
particularly for the case of buses in hot/tropical environments such as Spain, where labour laws often force vehicles to be kept at low temperatures for cleaning and maintenance staff. This in effect forces the vehicle engine-on condition to power the AC system. An additional benefit of
the MAGSPLIT system is that it can operate even whilst the engine is switched off, further enhancing fuel savings. This also eliminates the need for secondary cab roof type independent air conditioning systems. Consumers benefit from a reduction in
fuel consumption and reduced fares, but also by increased comfort within the vehicle. In hot environments, start/stop functions are often disabled so that traditional AC can function, maintaining passenger comfort. This hinders objectives to reduce local pollutants. The mCVT function allows full AC function at engine-off, providing both comfort and economic benefits. The torsional vibration isolation capability of MAGSPLIT insulates the engine vibration from the AC compressor, thereby improving compressor life and reducing overall service requirements and maintenance costs for the AC system and other driveline components.
DEMONSTRATIONS Emissions control business Eminox is working with Magnomatics to demonstrate this technology. Partly funded by an Innovate UK grant of almost £300k, the Vaircon project aims to reduce the environmental impact of passenger vehicles through mild hybridisation to reduce
CO2 emissions and lower fuel consumption. By bringing together Eminox’s skills in
integrating emissions reducing technology and 36 DESIGN SOLUTIONS JULY/AUGUST 2021
Magnomatics’ MAGSPLIT allows a vehicle’s air conditioning
compressor to operate dependently from the speed of the engine
Magnomatics’ MAGSPLIT electromagnetically operated transmission, the project will enable passenger transport vehicles to run air conditioning systems without the engine in operation for approximately 30 minutes. Working together, the project partners will develop this innovative new solution, tailored to meet the exact requirements of each vehicle type. Once created, tested and proven it will be manufactured in the UK. The prototype MAGSPLIT has now been
extensively tested on Magnomatics’ advanced dynamometers at its facility in Sheffield. The next stage of the project will be the testing of the MAGSPLIT with a compressor coupled to a bus AC roof box system. This will take place at the Millbrook proving ground in Bedfordshire to confirm system and cooling efficiency and determine potential fuel savings.
Magnomatics
www.magnomatics.com
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