Design and Fabrication of a Smart Automotive Air Conditioning System for Passenger Cars with Adaptive Thermal Control

Amol More

Automotive Air Conditioning; Smart HVAC; Refrigerant Cycle; Thermal Management; Passenger Comfort; Energy Efficiency.

Passenger comfort and energy efficiency are critical performance parameters in modern automobiles, especially under varying climatic and operating conditions. Conventional automotive air conditioning (AC) systems operate at fixed or manually controlled settings, often resulting in excessive energy consumption and non-optimal cabin comfort. This study presents the design, fabrication, and implementation of a smart air conditioning system for passenger cars based on thermodynamic optimization and adaptive control. The system integrates core refrigeration components including compressor, condenser, expansion valve, evaporator, and receiver dryer with intelligent sensor-based control for temperature, pressure, and cabin load variations. The proposed system dynamically regulates refrigerant flow and compressor operation using real-time feedback to maintain optimal thermal comfort while minimizing energy consumption. Component selection, hose fabrication, system assembly, vacuum testing, and refrigerant charging procedures are detailed. Comparative analysis between conventional and smart control modes demonstrates improved cooling response, reduced compressor cycling losses, and enhanced system reliability. The developed smart AC system provides an effective solution for customized vehicle applications, vintage restorations, and energy-efficient automotive thermal management.

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