tcp doc vivec rehman
TRANSCRIPT
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Technically Complex Project
Low Power Air Cooling device for
middle class bedrooms
Vivec Rehman
PG Product Design 2009
National Institute of Design
Guide : Prof. Praveen Nahar
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Initial Design Brief
Energy reuse in domestic
environment
Tapping the mechanical energy from a fan/air
conditioner to power other appliances in order
to make more efficient use of
electricity
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Overview of Research
Initial market and internet research of air coolers, air
conditioners and ceiling fans.
Observation of usage pattern of the above products among
users. Questionnaire and interviews at middle class residential areas
covering most age groups.
Open discussions at households to understand how a family
or group of families perceives an air conditioner
Discussing Technological innovations and the basics of HVAC
with experts from the industry.
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User Feedback and Inferences An air conditioner is considered a luxury
in middle class homes.
People change their sleeping position in
summers so that the fan is above them
so they do not use an AC because fan is
in the middle of the room while bed is
in a corner.
When air conditioner blower is not
close to the bed, people set a very low
temperature which increases electricitybills drastically.
A window AC produces too much noise
so nowadays people use split ACs only.
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Users often set the temperature very
low for a few hours at night and then
increase it in order to save electricity
but it consumes more electricity.
Conscious consumers use the timer
mode and set a constant temperature
of around 24c.
A single air conditioner can increase
the bill by 1.5 to 2 times in summers.
Users also say that expensive 5 starrated ACs do not make a vey big
difference in the bill.
User Feedback and Inferences
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Users also keep the fan switched onalong with the AC because the ACblower does not provide very efficientair circulation.
Air conditioners are installed in
parents room small children sleepwith the parents in summers.
None of the users own an air cooler. Afew used to have an air cooler earlier.
There is a problem of dust
accumulation on fans. Has to becleaned very frequently in dustyplaces.
User Feedback and Inferences
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Old people feel uncomfortable becauseof choppy effect of air from ceiling fans.
Ceiling fans are about 1.5 feet below theceiling.
Split ACs are 8ft above the floor on wallsadjacent to the bed.
Installation and maintenance has to bedone by professionals and is difficult inhigh rise buildings .
Window ACs block the entire windowand cannot provide efficient circulationbecause they are at a lower height thansplit ACs.
User Feedback and Inferences
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People prefer split ACs over portable ACssince they do not occupy any floor spaceand look neat even though split ACshave longer installation procedure.
Most families have just a fan in thebeginning and later upgrade to an A/C.
Ceiling fans have 5000cfm airflow whileair conditioners have 4 cfm/sqft air flow.
A\Cs are used max. in summer(6-8 hrs
per day),5-6 hrs in monsoon and 0-2 hrsin winter.
In old houses wiring has to be changedwhen installing an A/C since it usuallyrequires high current
User Feedback and Inferences
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General Layouts of bedrooms
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Pictures from Research
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Market Research
Air conditioners in the Indian Market areusually vapour compression type in split or
window configuration.
Thermoelectric air conditioners are used in
the telecom industry for localised cooling.
Cost is pretty low but increases if cooling isdesired for a larger area.
Portable ACs are now available but have
very low acceptibility.
Split ACs are gradually taking over the sales
charts because of low noise, betterlooks and efficient circulation.
People buy air coolers only in dry and hot
places like Madhya Pradesh and Rajasthan
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Cost of ceiling fans may vary from Rs. 1500to Rs 4000 or more.
Only a few high-end fans have remotecontrols.
Bladeless fans are fancy and are sold atvery high prices (Rs 12000 for table fan).
Solar powered air conditioning has beenintroduced in large installations.
Split ACs cost around Rs 25000 whilewindow ACs cost around Rs 18-22000.
ACs with 5 star rating cost almost Rs 8ooomore than normal ACs and recovery timefor extra cost is high.
Market Research
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The major companies making ACs are LG,Samsung, Onida, Hitachi, Daikin, Videocon,Haier, Voltas and Electrolux.
There are local and Chinese manufacturers
who sell ACs at a relatively low price butconsumers do not trust them because ofpoor service networks and marketing.
Cost and energy consumption are majorfactors guiding the choice of consumers.
Colours of most air conditioners are whitebecause walls are also white in colour.
Ceiling fans are either white or dark brownin colour.
Market Research
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OpportunityMapping
There is an opportunity to combine the ceiling
fan and air conditioner blower into one unit
which is ceiling mounted for better circulation
and increase the utility of the product.
Ceiling fans are not configurable so they cannot
cover the entire area of the bedroom.
There is no low power air conditioner available in
the market that provides localised cooling.
People have been making such coolers in foreign
countries at home to provide cool air in a
particular space of the room.
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Technology Used
The blower is based on the principle ofviscous shearing of air.
The air escape at high speed from a slitcauses air around it to be dragged with itcreating a low pressure area which draws inmore air thus creating a laminar flow of air.
Thermoelectric outdoor condenser unit isused to chill brine/refrigerant and send itthrough the heat exchanger built into the airhandling unit in the room.
A smaller capacity compressor(DanfossBD50) used in truck cabins could also beused in place of the thermoelectric unit.
Both thermoelectric and Danfosscondensers are used in trucks and caravans.
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Design Brief
Air ventilation and cooling device for middle classhouseholds (bedrooms)
A split system with condenser outside the house.
Will be able to replace a conventional ceiling fan .
Reconfigurable design so that the flow of air is
directly on the bed where 2 people are sleeping. Has a dust filter and ioniser to control dust and air
borne bacteria.
Installation easy with minimal changes to existing
connections and fixtures
Can be connected to an Air conditionercompressor(centralised cooling) as well as a
thermoelectric brine based cooling system(localised
cooling)
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Cost under Rs. 12000.
Adequate airflow for 120 sq.ft. room(size of
bedroom in middle class homes).
Efficient and flexible airflow distribution so that
a higher temperature setting can be used.
Adjustable speed and low power DC motor forimpeller.
Adjustable temperature(18-30c), blower
vent,speed and timer via remote control.
Easier to clean than a ceiling fan and replace
dust filter.
Glossy texture for a clean and dust free feel.
Dimensions : L 1800 X B 1500 X H 200(in mm)
Weight of air handling unit 6 kg (with heat
exchanger)
Design Brief
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Power consumption of air handling unit- 90 W Max Power consumption of condenser unit- 400W
Size of outdoor unit 320 X 180 X 250 (in mm)
Noise not more than 40dB
Split unit when used as an A/C for better sound insulation
Weight 7 kg max of outdoor unit
No heavy ducting required as in case of portable air
conditioners.
Could be operated directly using solar energy since it uses
a DC motor and thermoelectric unit.
Condenser unit is easy to mount and remove formaintenance.
Design Brief
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MoodBoard
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Product Placement
The product shall be an air conditioner for localised cooling i.e. for the
area where people are sleeping.
It will be positioned between an air cooler and a high end air conditioner.
It shall circulate cold air in that particular area and not in the entire room.
The blower unit can be used as a ceiling fan and can be configured
according to the occupants of the room and season in order to provide
airflow in the area where people are sleeping.
Ambient temperature of the room will eventually drop but the rate will
not be as fast as a 1 ton AC.
It will have power saving functions like timer.
It will also have dust filter and ioniser in the central blower to clean air in
the room.
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Technical Details
6 Thermoelectric modules 40 X 40X 6 (in mm)
6 X 50 = 300 W
Heat sink aluminum 250 X 200 X 120 (in mm)
2 Fans 120 X 120 X 20 (in mm)
2 X 20 = 40W Pump 80 X 50 X 50 (in mm) 30 W
Size of 2 copper reservoirs 250 X 120 X 40
volume of brine stored 2 X 1.2 = 2.4 litres
4 pass heat exchanger on both reservoirs
1100 -1500 W cooling capacity
Condenser unit
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3 high speed blower motors (100000rpm)
100 length X 80 dia.(in mm) 3 X 35W = 105 W
1 high torque motor to change position (300rpm)
80 length X 60 dia (in mm) 20W Heat exchangers on both sides 400 X 100 X 40 (in mm)
Airflow of individual blower 1500 cfm
Technical Details
Air handling unit
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Configuration of outdoor unit
Circulation pump
2 brine solution cases
Exhaust fans
Heat sink
6Thermoelectriccouples
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Configuration of Air handling unit
Dust filter
Position control
motor
Blower motor
Heat exchanger
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Concept Explorations
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Concept Explorations
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Concept Explorations
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Concept Explorations
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Concept Explorations
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Concept Explorations
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Digital renders of concepts
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Mock-ups w.r.t bedroom
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Outdoor unit CAD model
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Exploded view
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Blower unit CAD model
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Blower unit CAD model
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Exploded view
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Blower unit CAD model
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Display on Blowers
Each blower will have a separate display.
Display will show speed of the blower in the form of a bar graph
and a red/green light to show on/off.
Speed of each blower can be set individually.
Graph for speed will have 5 bars. Speed will be represented with
blue light while other bars will be white in colour.
When speed is being changed for a blower, the light will flicker to
notify which blower is being controlled.
Both blowers can only be moved together. Lights shall be covered by a frosted screen so that it is not too
bright for people who are sleeping.
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Remote Control Buttons A/C on, mode,Up/down keys, blower selector, blower on/off,
position change. There is a display for the temperature status of individual blowers and the
mode.
Mode has functions like Jet cool and timer.
When the unit is switched on using the on/off button at the top, it enters thefan mode.
To switch on the air conditioner mode, the user has to press the a/c buttonwhich will be backlit when a/c is switched on.
To change speed of individual blowers, the particular blower button is pressedfollowed by up/down key to change speed
Pressing the up/down button without selecting a blower would changetemperature.
To change position, press the POS. button along with up/down key to move
blowers forward and backward. To go to Jetcool mode press mode once and then POS. to start jet cool for 15
minutes
To set timer, press Mode twice and set time using Up/Down key and selectusing Pos.
Size 100 X 80 X 10 (in mm). Button size not less than 1 cm each.
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Remote Control CAD model
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Exploded view
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Orthographic DrawingsBlower unit
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Orthographic DrawingsOutdoor unit
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Orthographic DrawingsRemote Control
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Outdoor unit render
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Outdoor unit render
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Blower unit render
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Blower unit render
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Blower unit render
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Remote control render
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Colour and texture
White colour has been chosen as the basic colour of all three parts
to give a clean feeling and to make it less conspicuous when fixed
on a white ceiling.
Rubber parts are made like pipes and suction cups, buttons for
remote control are made in a very light blue colour.
A few plastic inserts are made light green in colour. All parts except the rubber parts have a medium gloss texture for a
clean and high tech feel.
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Materials and Manufacturing
Each blower is split into 2 parts horizontally that are injection
moulded in ABS with stainless steel inserts to provide structural
rigidity and strength.
These parts are then screwed together for assembly.
The removable heat exchanger and dust filter parts are made in PP.
Slot for the movable blowers is made of nylon for friction
resistance.
Rubber parts are moulded in nitrile rubber.
Frame is fabricated from Mild steel and powder coated in a dull
silver colour.
Blower unit
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Front and rear sections are formed in sheet metal and the mid
section is cut and welded to the rear part
The heat sink and other parts are mounted on the rear part.
The injection moulded HDPE hand grips are then stuck to this part
using industrial glue and then the front cover is screwed on.
Pipes for heat exchangers are taken out from the rear.
Materials and Manufacturing
Outdoor unit
Remote control
The remote control is split along horizontal axis into two injectionmoulded LDPE parts and the battery cover is also injection
moulded LDPE.
The screen is polycarbonate and buttons are neoprene rubber.
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Unique Features A Hybrid between an air conditioner, air cooler and ceiling fan.
Can direct its airflow usefully to provide comfort to occupants of the roomso the cooling is a combination of sensitive cooling of the AC andevaporative cooling due to moisture on the skin.
Can provide sensitively cooled air to the place where people are sleepingrather than circulating it throughout the room so less power is required.
Since air is first cleaned and then passed through the fan, it does not
require cleaning of accumulated dust like traditional ceiling fans. It uses the mounting hook of the traditional ceiling fan so no extra fitting
are required.
Remote control is provided with timer and jet cool option.
Temperature up to 18c can be set.
Less than 50% power consumption compared to a 1 ton AC.
Airflow is laminar unlike the turbulent flow of ceiling fans so people do notfeel uncomfortable when sleeping under it.
May also be operated directly on solar power since all the components areDC .
Low noise compared to a ceiling fan since motors are brushless DC type.
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Prototype
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Prototype
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Prototype
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Costing
Motors 3 X Rs 800 = Rs 2400 Heat Exchangers 2 X Rs 1000 = Rs 2000
Slider motor Rs 300
Metal parts Rs 1000
TECs 6 X Rs 800 = Rs 4800
Heat sink Rs 1000
Indoor panels Rs 2000
Outdoor panels Rs 1000
Total Rs 14500
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Feedback
U
sers were amazed to see a fresh new concept for the run of the mill airconditioner. They also liked appreciated the fact that it could replace a fan
too. They were also impressed about the slimness of the device and its
claimed airflow pattern generated by its form. The low power
consumption and strategy of cooling the area above the bed was also
appreciated. The futuristic form of the sliding blowers was also quite
intriguing for them. The compactness of the outdoor unit also drewconsiderable attention.
However, a few users expressed concern about the mechanism of sliding
the blowers and suggested it should be more sturdy. They also suggested
that I should conceal the pipes inside the metal tubes holding the entire
unit on the ceiling. They also said they would rather prefer something thatis more firmly fixed to the ceiling even if a few hole have to be drilled for
screws.