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The first challenge to properly size a vehicle A/C system is to define the vehicle air conditioning heat load requirement. Within automotive industry, a model to accurately define vehicle heat load is still under development. In this study, a simple method to calculate vehicle heat load is developed. The cooling load temperature differential (CLTD) method[1] is used to calculate the heat gain of a sunlit roof and wall (door). This is done in one step by using ASHRAE data. The calculation presented here takes into account the geometrical configuration of the vehicle compartment including glazing surfaces (shading), windshield and roof angle, and vehicle orientation, Special attention is given to the calculation of direct and diffuse incidence solar radiation through the windshield and skylight glass. The vertical glass' solar heat gain is evaluated by using ASHRAE[1] data. The U value method is used to calculate heat transfer between the outside and inside cabin.

Oil in circulation (OIC) in a vehicle AC system is an index to demonstrate the system having a proper oil charge. A well lubricated compressor is key for AC system, as it relates to compressor durability. The challenge that climate control development engineering faces is how to correlate OIC from test to test (test stand to vehicle level etc.). In this study, a method to correlate vehicle AC system OIC from test-to-test, stand to vehicle is developed. The study found that oil charge amount ratio, refrigerant mass flow ratio, and vehicle engine speed ratio are the key factors to correlate the test results such as stand versus vehicle, vehicle test A versus test B etc. To further reflect compressor oil lubrication conditions, compressor compression index (polytropic number) is computed for the different testing, and the ratio of compression index is also introduced to the correlation. The method accuracy was validated by multiple vehicle/stand tests.