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2024 Update Coming Soon Published Date: June 2022 Number of Pages: 113
The heating, Ventilation and Cooling(HVAC) of a car is a major criterion in a buyer`s purchasing experience as it has a direct effect on the cabin comfort and overall driving experience.
Till the early 2000s, >97% of cars produced had reciprocal compressors, which sapped engine power to compress the intake ambient air. But, now as the industry progresses towards fuel-efficient and electrified cars, electric/scroll compressors are getting prominence.
The first shift from the reciprocating compressor to the E-compressor started happening in the 2012-2013 time frame when European luxury car manufacturers started using it in their luxury cars to improve fuel economy by 2-3%.
More than E-compressor, the market was driven towards a variable displacement compressor, which was in line with the growth in other ancillaries like variable displacement oil pumps and electric coolant pumps.
Then, the volume shift was driven by fuel economy benefits and vehicle electrification trends but the reach was limited to higher-segment cars. The move to e-compressor gained real momentum only after 2015 when sales of low-cost Chinese branded electric vehicles in China started growing by 100%.
To learn more about the Global Electric Coolant Pump Market, read our report
In EVs, the use of air conditioners and other electronic components has a significant impact on the cruising distance.
To address the issue Sanden will combine its air-conditioning expertise with Nidec’s traction motor and inverter expertise to accelerate the development and commercialization of an integrated thermal management system for air-conditioning and drive systems for future electric vehicles.
Denso included its first electric compressors into the product line-up first in 2012. Denso was responsible for the world’s first mass-produced electric compressor with an integrated inverter and motor.
In terms of e-compressors for passenger cars, they were first installed in Ford’s Focus electric vehicle in 2012. Denso has been the world’s largest OE supplier of A/C compressors. As per the company, its thermal management technologies including engine cooling are fitted as original equipment to almost 25% of European cars.
The market for electric HVAC systems will be directly proportional to the growth experienced by the development and sales of electric vehicles. New programs with incentives for the production of electric vehicles by governments and other investors will drive the growth of the industries that supply automotive components and systems.
For instance, in June 2020, Germany announced a stimulus plan worth EUR 130 billion with approximately EUR 8 billion for the support of electric vehicle sales and manufacturing. In China, the subsidy program placed for the purchase of PHEVs and battery EVs has been extended to the year 2022 due to the COVID-19 pandemic to support the automotive sector.
In November 2019, Pierburg developed an “Electric Climate Compressor” driven by an electric motor. The new unit is of compact design so that it can fit in the usual installation spaces and serves the regular voltage levels HV2 and HV3. The three modules—mechanical compressor unit, electric motor and power electronics—are modularly integrated.
Many solutions are needed for e-mobility, and MAHLE is leading the way. In terms of both cost and performance, the battery is one of the most significant components in an electric car. Its importance is thus comparable to that of the internal combustion engine, and it requires just as much attention. Maintaining the proper battery temperature affects not just the battery’s service life, but also how quickly it can be charged and even the vehicle’s cruising range. You will get the most out of your battery if the temperature is correctly regulated and the capacity is carefully managed.
The MAHLE electric compressor is already at the heart of the air conditioning and refrigerant circuit, ensuring that the proper cabin temperature is maintained.
It is now a significant component in the e-mobility drive system, as it is at the centre of the battery cooling function, maintaining the correct battery temperature. Because if the battery performs well, e-mobility will as well, to the point where it can be seamlessly integrated into daily life.
In China, EV Sales in 2020 witnessed a continuous drop in sales over the 6 months. Phasing out of subsidies for EVs and the pandemic outbreak are the chief reasons for this.
The Dual credit policy expected to replace the subsidy policy is estimated as the main driver of Chinese EV sales in the future. The EV sales are expected to make up about 25% of the new car sales in 2025 and the policy is estimated to play a crucial role in this.
As the market is suffering from a shortage of semiconductor chips and electronics due to the pandemic the sales of vehicles in China declined by 17.8% in August 2021 to 1.8 million vehicles sold. However, the demand for electric vehicles is on the rise creating a difficult situation for OEMs to manufacture vehicles with the ongoing semiconductor shortage.
The company BYD received orders for plug-in EVs of over 60,508 units in August which was a whopping increase from the previous months. The company has reported delivery of over 40,000 plug-in EVs in China during June of 2021 setting a record in the automobile sector. The units were 207% more than the units sold a year ago with plug-in vehicles constituting about 81% of the total sales of BYD.
The sales of plug-in EVs have surged in China as multiple models are being sold by several OEMs. June of 2021, alone recorded registration of 235,000 plug-in EVs which is approximately more than 160% compared to the year 2020. The market share has also increased to 15% where 12% are BEVs. For the year 2021, over 1.1 million EVs are sold which constitutes 11% of the total market with 9% BEVs.
Post-COVID, we are witnessing protectionist policies in auto component sourcing play out at a much higher level than before. As per a recent announcement(3rd June 2020), GM is not planning on importing any major EV components and will source all of them domestically at competitive prices.
In Europe, in Jan-May 2020, the EV share of new car sales was 7.8% as compared to 3.6% in 2019(Full Year). German and France governments have announced generous incentives for buying EVs only. In France, the incentives bring down the cost of a $ 40,000 EV to as much as $ 26,285 (when trading in older ICE cars).
In Europe, the share of battery electric vehicles has increased to 7.6% in the first half of the year 2021 which is a significant increase from the year 2020 which saw an increase of only 4.3%.
The EV sales in Europe saw a significant rise during the second quarter of 2021, the new car registrations from plug-in EVs increased to 237,934 which was an increase of 157% year-over-year. There has been a total of over 1 million car registrations for plug-in EVs in the year 2021 in Europe which constitutes 16% of the total market out of which 7.6% constitute BEVs
The sales of electric vehicles increased by 50% in Iceland, 25% in the Netherlands as well as 30% in Sweden. Norway reported a record high sales of electric cars of 75% which was about one-third from the year 2019. The United Kingdom has reached the number of registrations twice the previous year to 176,000. Germany has registered 395,000 new electric cars as well as France registered more than 185,000.
The Volkswagen Group reported deliveries of more than 342,000 BEV as well as PHEV slit 50/50 in the second quarter of 2021. The figures have increased at a tremendous rate of over 260% for BEVs and 227% for PHEVs. They have sold the maximum number of cars in Europe acquiring 26% of the market share followed by the US and China for the year 2021.
The BMW Group has reported more than doubled sales volume to 83,000 in the second quarter of 2021 and 153,000 in the first quarter of 2021. The share of the plug-in EVs has increased by a whopping 11.85% of the total BMW volume. With 36,089 BEVs and 117,178 PHEVs sold in the first half of the year 2021, the sales for the group have been up by 183.9% and 139.4% respectively during this year.
The market in the USA has been considerably performing low after the pandemic, the automotive car market declined by 23% in 2020 however, the registrations of new EVs fell less than others. In the year 2020, new cars registered about 295,000 out of which 78% were BEVs which was low from 327,000 in March the previous year.
The market in Canada is recovering slowly, the number of new vehicles registered in Canada during the first quarter of the year 2021 was 11.8% more than in the same term of 2020, the electric vehicles saw an increase of 1.1% to 4.6%. In total across Canada, the battery electric vehicles registered were 12,693, hybrids were 14,278 and plug-in hybrid vehicles were 4,592.
In India, automakers that manufacture electric vehicles sold 121,170 units during the first half of the year 2021 which was a significant rise from the 119,647 units sold during the whole previous year 2020. Tata Nexon has consistently been the bestselling electric vehicle in the Indian market with sales of 1,022 units in June which was an increase of 234% year-on-year.
The automotive component and HVAC system manufacturing companies suffered due to the impact of the pandemic with revenue recorded less than the previous years.
For instance, the company Hanon Systems recorded a revenue worth $5.7 billion in the year 2020, which was a decrease from the revenue recorded worth $6.02 billion in the year 2019. The plunge was attributed to the low demand and halt in manufacturing activities globally.
The present market size is driven by growing BEV sales in China but in Europe, it’s the replacement of Diesels by 48V Mild hybrids that are driving the market.
In 2019, Shanghai Highly group witnessed a YoY increase of 7.4% in the Automotive HVAC market, as the sales volume reached 30,680,000 units. In the case of electric scroll compressors, they achieved a sales volume of 188,100 units, 86.93% up on a YoY basis. Highly’s market share in new energy vehicles accounted for 15% with 7% points up on a YoY basis.
Reciprocal compressors are still the dominant HVAC technology for the automotive application, accounting for >70% of the market but the electric scroll compressors are expected to grow at more than XX% CAGR during the next 5 years. To learn more about the Electric Vehicle HVAC market– read our report
The global automotive electric HVAC compressor market size in terms of volume is estimated at XX Million units in 2022 growing at a XX% CAGR till 2030.
The adoption of electric vehicles (EVs) is increasing rapidly worldwide, driven by the rising awareness of environmental concerns and government initiatives to promote EV adoption. EVs require electric HVAC compressors to provide heating and cooling for the cabin, which is driving the growth of the automotive electric HVAC compressor market.
Autonomous vehicles require reliable and efficient HVAC systems to maintain a comfortable temperature in the cabin, even when the vehicle is not in motion. This is driving the demand for electric HVAC compressors for autonomous vehicles.
SiC and GaN semiconductors are more efficient and have a higher power density than traditional silicon semiconductors. This makes them ideal for use in electric HVAC compressors, as they can help to improve the efficiency and performance of electric vehicles.
Electric vehicles are becoming more powerful and efficient, and this is driving the demand for high-performance electric HVAC compressors. High-performance electric HVAC compressors can provide more cooling capacity and can operate in a wider range of temperatures, which is essential for electric vehicles with high-performance motors and batteries.
The Calsonic Kansei e-HVAC Compressor marks a significant advancement in automobile climate control systems, ushering in a crucial shift to more sophisticated and environmentally friendly cooling techniques. The e-HVAC compressor is a key advancement in how cars regulate their internal temperature and comfort at a time when the automotive industry is transitioning to electrification and environmental consciousness.
The Calsonic Kansei e-HVAC Compressor is a model of modern electric compressor technology at its core. The e-HVAC compressor runs on an electric motor rather than the engine power that traditional air conditioning systems rely on through a belt. Greater efficiency is provided by this deviation from the conventional architecture, which also eliminates mechanical losses.
The e-HVAC compressor coincides with the industry’s objective of attaining improved fuel economy and reduced emissions through optimizing energy use. The Calsonic Kansei e-HVAC Compressor stands out as a responsible solution as the automotive industry places more and more emphasis on sustainable practices.
Beyond environmental factors, the Calsonic Kansei e-HVAC Compressor has many benefits. Its fast responsiveness and accurate temperature regulation greatly enhance passenger comfort. The quick temperature changes made by the compressor make the interior of the vehicle more comfortable and cosy for passengers, improving the driving experience as a whole.
Additionally, because of its modular construction, it can be easily integrated into a variety of vehicle platforms, showcasing the automakers’ adaptability and flexibility in integrating this technology across their whole lineup of vehicles. The Calsonic Kansei e-HVAC Compressor is an example of how the automobile climate control industry has innovated.
This solution advances automobiles toward greater efficiency, lower emissions, and increased passenger comfort by incorporating electric compressor technology. It highlights the industry’s dedication to advancing environmentally friendly solutions that support overall sustainability goals.
The paradigm-shifting change in automobile temperature control is embodied by the Delphi e-HVAC Compressor. It uses electric motor-driven technology instead of more conventional systems that rely on engines.
By reducing mechanical losses, this innovation not only increases efficiency but also makes precise, independent climate control possible. The adaptive operation of the compressor maximizes energy utilization, promoting fuel efficiency in internal combustion vehicles and extending the range of electric vehicles.
The use of environmentally friendly refrigerants and cutting-edge sealing techniques, which reduce emissions and refrigerant leakage, highlight its concern for the environment.
Passenger comfort is increased through prompt responsiveness and precise temperature control. Increased integration flexibility between vehicle types is a benefit of modular design. By lowering pollutants, preserving energy, and improving driving experiences, the Delphi e-HVAC Compressor is a symbol of sustainable development.
The technology company Rheinmetall has a contract to offer an electric air conditioner compressor that was recently created specifically for electric vehicles from a well-known, worldwide operating system partner of the automotive industry.
The order, which represents a total sales volume of €80 million, is another achievement for Rheinmetall’s electrification strategy, which includes the creation of new drive components to lower CO2 emissions as well as the constant improvement of existing ones.
The Group continues to create cutting-edge products in this industry because it has identified electrification as a global megatrend and a significant growth driver for its business during its strategic realignment process.
By obtaining the order for an electrically operated air conditioner compressor, Rheinmetall strengthened its position in the fiercely competitive thermal management market and can now anticipate additional orders from illustrious businesses operating across numerous sectors.
The new air conditioning compressor will be manufactured at the Rheinmetall facility in Abadiano, Spain, a Group centre of expertise for coolant products.
Rheinmetall provides a full range of system components for conveying and regulating fluids for thermal management in contemporary e-vehicles, all from a single source, with its new a/c compressor, electric expansion valve for coolants, and a well-established assortment of coolant pumps and coolant valves.
In August 2021, Brose announced the launch of a new system for thermal management for electric vehicles that increases the efficiency of the electric vehicle without reducing their range and comfort.
In April 2021, to enhance the quality of production Toyota Industries Corporation and Siemens came together to develop an AI that can predict product misbehaviour in aluminum die casting, an important process in automotive air conditioning compressor production
In February 2021, MAHLE announced the launch of a new high-voltage PTC heater for electric vehicles which helps in extending the vehicle’s cruising range. The intelligent system uses heating elements and integrates the built-in electronics to continuously analyse the electrical resistance of the PTC elements in the heater to adjust the temperature.
In January 2021, the JV of Marelli Corporation K.K & Highly Group was officially established. The JV is called “Highly Marelli” which will focus on developing HVAC solutions for customers and suppliers specifically in electrification of compressors, heat pumps and heating, ventilation & air conditioning and electric-driven compressor systems.
Eaton’s Vehicle Group has developed a series of 48-volt technologies to assist its commercial vehicle customers in transitioning from traditional 12- and 24-volt vehicle systems to systems that include a 48-volt set-up. An electrical engine cooling fan and electric air conditioning compressor are also under development
Hanon Systems’ Pyeongtaek plant in South Korea produced its 100 millionth compressor. The plant was established in 1991. In December 2020, Hanon Systems announced the launch of a new, eco-friendly and innovative refrigerant-based R744 heat pump for Volkswagen. The new system is designed primarily for electric vehicles which will enable consumption of low power even in sub-zero temperatures.
In December 2020, Toyota introduced the 2nd-generation Mirai fuel cell electric vehicle. It consists of an electric air compressor that pressurizes the intake air and a water-cooled intercooler that reduces the temperature of the compressed air before it enters the Fuel Cell stack.
In October 2020, Toyota Industries Compressor Parts America invested about $5.5 million to expand its production facility in Georgia. They are currently manufacturing HVAC compressors for automotive applications. They supply automotive compressors to various OEMs few being Toyota Motor Corporation, Chrysler, Ford and General Motors.
For hybrid vehicle applications, Toyota Industries Corporation has created an electric compressor, DC-DC converter, rear inverter, and AC inverter. These components will be used in Toyota Motor Corporation’s upcoming Prius.
This time, the electric compressor, DC-DC converter, and AC inverter are all smaller and lighter than those used in current Prius models. A forced air conditioning system is also used in the rear inverter that will be installed in the Prius’ first 4WD model.
Toyota Industries is expanding measures for attaining a society with a decreased environmental impact through technological advancements in the environmental and energy domains, and this will contribute to the creation of ever-better Toyota cars that will make consumers happy.
A reference design for high-voltage air conditioning compressors has been released by Arrow Electronics. The circuit board can accommodate high-voltage electric car compressors and is made for electric vehicles with 320V batteries. The controller in this design is an automotive-grade SPC560. The board’s input voltage is 320V, and its maximum output power is 3.5kW.
It provides overvoltage, undervoltage, overcurrent, and overtemperature protection and has high-efficiency and high-pressure start-up, low noise, and speed closed-loop control.
The reference design, which can be applied to products like car refrigerator compressors and air conditioning compressors, uses ST’s SPC560P50L3EFA microcontroller, L6498L gate driver, STGWA50M65DF2 IGBT transistor, and other core chips. It has a 96% operating efficiency, supports sensorless FOC control algorithm, and supports CAN, LIN, and PWM control.
With the rapid development of electric vehicles, the demand for electric vehicle air-conditioning compressors is also rising and market demand is high.
Vehicles powered by electricity and traditional fuels both have similar air conditioning systems. The electric vehicle uses an electric compressor integrating the motor, compressor, and circuit to drive the air conditioner, and the electric vehicle compressor is driven by high-voltage electricity provided by the power battery. In contrast, the traditional vehicle compressor is driven by the engine gearbox belt through the electromagnetic clutch.
The electric energy of the power battery pack is used directly to power the electric car compressor. The spinning speed of the compressor is controlled by a control device installed inside it that receives signals from the outside. A compressor with a small footprint can be used to reduce power consumption, extending the range of an electric vehicle.
In contrast to the compressor of a traditional fuel-engine vehicle, it is not dependent on engine speed, allowing the air conditioning system in the car to operate independently and not adding to the load on the power system on the one hand, and the compressor can operate at high speed on the other.
In a fuel-powered car, the engine drives the generator set, which then charges the battery and provides power to the air conditioner compressor, allowing the refrigerant’s work to be realised and the refrigeration effect to be achieved. Additionally, a fuel vehicle can fully utilise the waste heat that the engine produces while it is running to warm the coolant and achieve interior heating.
The battery powers the air conditioner in an electric car. The battery’s high-voltage direct current is transformed into low-voltage direct current by a DC/DC converter, which then supplies electricity to the electric compressor or other air-conditioning components to ensure their proper operation. The electric car compressor is powered by the low-voltage converted current, which also works on the refrigerant to produce the refrigeration effect.
ESTRA announced the availability of its ESR33 electric compressor, which is intended to enhance the efficiency of HVAC systems. The most demanding requirements for electrical vehicles are met by this electric compressor’s wide speed operating range and small size (33 cm3). The ESR33 meets both customer expectations and market development as part of ESTRA’s commitment to a greener world. It also helps keep the vehicle cabin comfortable.
One of the top manufacturers of electric compressors (EC) for commercial and heavy-duty applications as well as speciality vehicle markets worldwide is TCCI. Low voltage signals can accommodate both 12v and 24v within the same unit, enabling OEMs with applications in both Europe and North America to easily maintain their development programmes even when market-specific voltages differ. Electric compressors with a maximum output of 4 kW at 24 volts and a maximum output of 30 kW at 400 volts and 850 volts
Low voltage DC 12V scroll compressor unit called LD20A12AB electric AC compressor. which indicates that it creates a significant cooling effect by compressing the refrigerant (R134a) into the automatic AC unit using the “scroll” principle.
Guchen EAC DC12V electric compressor is becoming more and more popular in automotive HVAC systems due to its high efficiency and dependability. Improved efficiency LD20A12AB 12V direct current compressor for commercial vehicle electric air conditioning systems. Worldwide sales of low voltage automotive electric AC compressors at 12 volts. It is a modern, low-noise 12V DC air conditioner electric compressor.
The electric AC system that performs air conditioning in an electric car compartment is driven by an electric compressor. Guchen’s FD86A320AC variable-speed electric a/c compressor integrates the compressor, drive controller, drive circuit, and brush-less permanent magnet motor to allow the electric air conditioner to operate on its own.
The most recent inverter drive technology is used. The inverter converts DC voltage (it is capable of handling input voltages of up to 320 VDC) into the three-phase alternating voltage needed by the electric motor, allowing the speed of the compressor to be adjusted to suit the demands of comfort cooling for electric vehicles. Consequently, the HVAC systems utilised in electric vehicles will consume as little energy as possible.
The main benefit of a variable speed electric compressor is that it can be adjusted to run between 1000 and 5500 revolutions per minute depending on the temperature outside or the occupants’ preferences for temperature. Electric compressors with variable speeds use less energy and give passengers more comfortable interior temperatures.
About 72% of total automotive Electric HVAC compressors are manufactured in Asia. High technology maturity is the prime reason for that. Scroll compressors are fast replacing rotary compressors globally as well as in Asia.
Since the average cost of an electric scroll compressor lies between $XX-$XX, the suppliers predominantly manufacture in high volumes in Asia and get it shipped to Europe and North America.
The high scale protects the margin and the added burden of long-distance transportation. As of now, most of the suppliers are working on reducing the weight and size of compressors to make them an easy fit for mild-hybrid architecture.
The New compressor development by suppliers is focused on five major themes i.e. Efficiency, Flexibility, NVH, Eco-Friendly refrigerant and cost.
Toyota Industries Corporation recently announced the results for the first quarter of the fiscal year 2022 with net sales worth $5.6 billion which was a significant increase of 43.2% from the net sales for the same term of the fiscal year 2021 worth $3.9 billion.
In April 2021, the company Sanden Huayu Automotive partnered with ROHM Semiconductor. The partnership is set to accelerate the technical development and innovation in the automotive sector for electric HVAC systems to the needs of the customers.
In September 2021, Hanon Systems announced the expansion of the company by opening two manufacturing units in Hungary. The manufacturing units will provide manufacturing space for equipment including the brazing, forming, bending and welding operations and assembly lines for testing of automotive air conditioning lines.
In May 2021, the company announced the acquisition of the condenser business from the company Keihin Corporation to expand the condenser technology of the company across Europe and North America as well as expand the customer base of the company.
In March 2021, Hanon Systems announced the expansion of the company globally by developing its fifth manufacturing unit in Korea. The manufacturing unit is set to offer a variety of developmental solutions for heat pump modules as well as coolant valve assemblies which will complement the electric vehicles for the Genesis brand and the Hyundai Motor group’s Ioniq 5 model.
Brose Fahrzeugteile has been very active in producing e-compressors locally in China. Brose is currently one of the very few electric HVAC compressor suppliers with local software development competence in China. The design of these HVAC compressors is made by the local car manufacturers.
Sanden will combine its air-conditioning expertise with Nidec’s traction motor and inverter expertise to accelerate the development and commercialization of an integrated thermal management system for air-conditioning and drive systems for future electric vehicles. Sanden’s Yattajima factory in Japan is capable of producing 750,000 units of e-HVAC compressors
In August 2019, Marelli, the subsidiary of Calsonic Kansei, entered into a partnership with Chinese firm Shanghai Highly Group expert for compressor manufacturing.
The JV is between the JCH (Johnson Controls-Hitachi Air Conditioning) and the Highly group. This will allow Marelli with greater access to the Chinese market and strengthen its business in EDC for passenger vehicles. The JCH holds 25% of the JV and the total investment in the JV is $38 Million.
In August 2018 MAHLE opened its first production plant for electric compressors in Balassagyarmat/Hungary. It started the production of e-compressors in 2019.
In 2019, Marelli’s revenue from the HVAC & e-compressor division was ~$ 857M
Valeo a leading thermal management system supplier gravitated towards e-compressors, as a result of developing an Electrically Driven Compressor (EDC) in early 2017. In Q1-2020, thermal systems witnessed 1,000 million Euros in business. South America witnessed higher sales in the Thermal Systems Group.
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