Technically Complex Project

Low Power Air Cooling device for

middle class bedrooms

Vivec Rehman
Guide : Prof. Praveen Nahar PG Product Design 2009
National Institute of Design
 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
 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.
 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 electricity
bills drastically.
• A window AC produces too much noise
so nowadays people use split ACs only.
 User Feedback and Inferences
• 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 24°c.
• A single air conditioner can increase
the bill by 1.5 to 2 times in summers.
• Users also say that expensive 5 star
rated ACs do not make a vey big
difference in the bill.
 User Feedback and Inferences
• Users also keep the fan switched on
along with the AC because the AC
blower does not provide very efficient
air circulation.
• Air conditioners are installed in
parents’ room small children sleep
with the parents in summers.
• None of the users own an air cooler. A
few used to have an air cooler earlier.
• There is a problem of dust
accumulation on fans. Has to be
cleaned very frequently in dusty
places.
 User Feedback and Inferences
• Old people feel uncomfortable because
of choppy effect of air from ceiling fans.
• Ceiling fans are about 1.5 feet below the
ceiling.
• Split ACs are 8ft above the floor on walls
adjacent to the bed.
• Installation and maintenance has to be
done by professionals and is difficult in
high rise buildings .
• Window ACs block the entire window
and cannot provide efficient circulation
because they are at a lower height than
split ACs.
 User Feedback and Inferences
• People prefer split ACs over portable ACs
since they do not occupy any floor space
and look neat even though split ACs
have longer installation procedure.
• Most families have just a fan in the
beginning and later upgrade to an A/C.
• Ceiling fans have 5000cfm airflow while
air 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 hrs
in winter.
• In old houses wiring has to be changed
when installing an A/C since it usually
requires high current
General Layouts of bedrooms
Pictures from Research
 Market Research
• Air conditioners in the Indian Market are
usually 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 is
desired 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, better
looks and efficient circulation.
• People buy air coolers only in dry and hot
places like Madhya Pradesh and Rajasthan
 Market Research
• Cost of ceiling fans may vary from Rs. 1500
to Rs 4000 or more.
• Only a few high-end fans have remote
controls.
• Bladeless fans are fancy and are sold at
very high prices (Rs 12000 for table fan).
• Solar powered air conditioning has been
introduced in large installations.
• Split ACs cost around Rs 25000 while
window ACs cost around Rs 18-22000.
• ACs with 5 star rating cost almost Rs 8ooo
more than normal ACs and recovery time
for extra cost is high.
 Market Research
• 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 but
consumers do not trust them because of
poor service networks and marketing.
• Cost and energy consumption are major
factors guiding the choice of consumers.
• Colours of most air conditioners are white
because walls are also white in colour.
• Ceiling fans are either white or dark brown
in colour.
 Opportunity Mapping
• 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.
 Technology Used
• The blower is based on the principle of
viscous shearing of air.
• The air escape at high speed from a slit
causes air around it to be dragged with it
creating a low pressure area which draws in
more air thus creating a laminar flow of air.
• Thermoelectric outdoor condenser unit is
used to chill brine/refrigerant and send it
through the heat exchanger built into the air
handling unit in the room.
• A smaller capacity compressor(Danfoss
BD50) used in truck cabins could also be
used in place of the thermoelectric unit.
• Both thermoelectric and Danfoss
condensers are used in trucks and caravans.
 Design Brief
• Air ventilation and cooling device for middle class
households (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 conditioner
compressor(centralised cooling) as well as a
thermoelectric brine based cooling system(localised
cooling)
 Design Brief
• 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 for
impeller.
• Adjustable temperature(18-30°c), 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
• 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 for
maintenance.
MoodBoard
 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.
 Technical Details
Condenser unit
• 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
 Technical Details
Air handling unit
• 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
Configuration of outdoor unit
Circulation pump

2 brine solution cases

Exhaust fans

Heat sink

6Thermoelectric
couples
Configuration of Air handling unit
Dust filter
Position control
motor

Blower motor
Heat exchanger
Concept Explorations
Concept Explorations
Concept Explorations
Concept Explorations
Concept Explorations
Concept Explorations
Digital renders of concepts
Mock-ups w.r.t bedroom
Outdoor unit CAD model
Exploded view
Blower unit CAD model
Blower unit CAD model
Exploded view
Blower unit CAD model
 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.
 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 the
fan mode.
• To switch on the air conditioner mode, the user has to press the a/c button
which will be backlit when a/c is switched on.
• To change speed of individual blowers, the particular blower button is pressed
followed by up/down key to change speed
• Pressing the up/down button without selecting a blower would change
temperature.
• 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 select
using Pos.
• Size – 100 X 80 X 10 (in mm). Button size not less than 1 cm each.
Remote Control CAD model
Exploded view
 Orthographic Drawings
Blower unit
 Orthographic Drawings
Outdoor unit
 Orthographic Drawings
Remote Control
Outdoor unit render
Outdoor unit render
Blower unit render
Blower unit render
Blower unit render
Remote control render
 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.
 Materials and Manufacturing
Blower unit
• 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.
 Materials and Manufacturing
Outdoor unit
• 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.

Remote control
• The remote control is split along horizontal axis into two injection
moulded LDPE parts and the battery cover is also injection
moulded LDPE.
• The screen is polycarbonate and buttons are neoprene rubber.
 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 room
so the cooling is a combination of sensitive cooling of the AC and
evaporative cooling due to moisture on the skin.
• Can provide sensitively cooled air to the place where people are sleeping
rather 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 18°c 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 not
feel uncomfortable when sleeping under it.
• May also be operated directly on solar power since all the components are
DC .
• Low noise compared to a ceiling fan since motors are brushless DC type.
Prototype
Prototype
Prototype
 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
 Feedback
• Users were amazed to see a fresh new concept for the run of the mill air
conditioner. 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 drew
considerable 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 that
is more firmly fixed to the ceiling even if a few hole have to be drilled for
screws.