EME3213 – MANUFACTURING AND

PROCESSING TECHNOLOGY

Name (as in SEGi ID): Abdullah Omair

SEGi ID: SUKD1901642
UCLan ID: SUKD1901642
Group ID:
Course Code: EME3213
Course Name: MANUFACTURING AND PROCESS TECHNOLOGY
Submission Date: 16/11/2020

QUESTION 1

1. ‘Wall-mounted air conditioner R32’

It is air conditioner operating with low global warming potential R32 refrigerant, it sets new
standards in aesthetics, efficiency and ease of use for best value goods and affordable comfort. It
is a high-wall residential inverter heat pump provides an elegant design that blends into any
interior.

‘R-32’ Characteristics

1. Depletion of zero ozone layer

2. Low potential for global warming

at 1/3 of R410A

3. 1.5 x R410A heat transfer

capability

4. Enhanced energy efficiency

5. Less effects on global warming

Design and its components

1. Elegant and slim-line flat panel style.

2. Energy Class A+/A+ cooling and heating modes ensure excellent energy savings and
unprecedented comfort.

3. Extremely quiet service Less than 22dB (A) in silence mode

4. Dustless coil (Special Aluminum Fine) for improved performance

5. Self-cleaning feature to prevent the formation of mold on the heat exchanger coil

6. 2D airflow control with horizontal motorized lovers: preset directions or automatic sweeping.

7. Good quality movement of air.

8. User-friendly wireless remote control

9. ECO Logic button to reduce energy consumption by 25%

10. Power booster to hit the comfort point set very quickly

11. Automatic Stop programmable

12. Self-diagnosis feature
13. Elegant white LED

Anatomy of Wall-mounted air conditioner ‘R32’

Evaporator:  This is basically a coil situated in your indoor machine, with a coolant running
through it. In cooling mode, the indoor machine, with the aid of a fan, constantly pulls these
cooling evaporator coils in hot air and blows them back into the room at a much lower
temperature. As the refrigerant absorbs heat, it converts from liquid to gas.

Compressor: The heat collected inside flows through the tubes to the compressor in the outdoor
unit. The main purpose of the compressor is to compress low-pressure refrigerant gas into a high-
pressure refrigerant gas so that the heat can be expelled outside.

Condenser: This is the second coil in the outdoor unit, which receives heavy, compressed
refrigerant gas. With the aid of a second fan, the heat is released into the outer atmosphere and
the refrigerant gas is condensed into a liquid.

Extension valve: This is the last bit of the riddle. In basic terms, it acts to control the progression
of the refrigerant to the evaporator (beginning the cycle once more).

Join the principle components of the gadget with a warmth trade circle. The coolant in the loops
of your unit goes between the indoor and open air units, taking warmth starting with one area
then onto the next. In summertime, the warmth is consumed from inside your home and depleted
from outdoor, thus making your house cooler
2. Review of materials (Manufacturing Process)
Manufacturing encasement parts from galvanized sheet metal and structural steel
‘Wall-mounted air conditioner R32’ it starts out as material which is raw rough unpolished or
also known as crude materials that are used as supporting steel shapes and sheet steel. As the
sheet metal is moved into assembling cells or work cells, it is cut, shaped, punched, penetrated,
sheared as well as twisted into a helpful shape or structure. Nooks or walled in areas, the metal
that covers most outside private units, are made of electrifies sheet metal that utilizes a zinc
covering to secure against consumption. Excited sheet metal is regularly used to shape base
skillet, face plates and different help sections noticeable all around conditioner. This sheet of
metal is sheared on a shear press in an assembling cell not long after it has shown up from
capacity or stock.
Punch moving the shapes of sheet metal

The sheet metal is piled from the shear push on a CNC (Computer Numerical Control) punch
press. The punch press has the decision of getting its PC programming from a CAD/CAM
(Computer Assisted Drafting/Computer Aided Manufacturing) program or from an
autonomously distributed CNC program. The CAD/CAM programming changes over the
composed or demonstrated segment of the machine into a record that can be perused by a punch
press, disclosing to it where to poke holes in the sheet metal. A large number of the sections are
produced using a looped sheet on a pressure driven or mechanical press where units of different
figures and setups can be formed and constantly unrolled into the unit.

Cleaning the parts

Before they are powder covered, all segments must be totally spotless and away from earth, oil,
oil, and ointments. To accomplish this necessary undertaking, distinctive cleaning techniques are
utilized. At the point when parts are lowered, enormous preparation tanks loaded up with a
cleaning dissolvable upset and knock off the oil. To knock off earth and oil, shower wash
frameworks utilize pressurized cleaning arrangements.

Powder coating

They are taken care of by means of a powder-covering activity until sections, dish, and coverings
are accumulated together. They are taken care of through a stall on an overhead transport, the
powder covering plan showers a paint-like dry powder on the pieces.

Bending the tubing for the condenser and evaporator

In cooling
frameworks, the
condenser and
evaporator both fill
in as a warmth
exchanger and are
made of copper or
aluminum tubing
twisted around
looking like a ring
to build the partition
through which the
working liquid
passes. As the
working liquid in
the evaporator pulls
its warmth away,
the restricting liquid, or cooling liquid, streams around the cylinders. This is finished by taking
twisted copper tubes with a few little widths in a similar structure and securing them with control
poles and aluminum plates. Prior to being taken care of through the drinking spree, tubing
provided to the provider in a loop shape experiences an uncoiler and straightener. Any tubing on
a harsh saw that will cut a few little cylinders in a single stroke will be cut into wanted lengths.
On a punch press, the aluminum plates are punched out and are shaped on a mechanical press to
eliminate any waves or divots in the plate.

Joining the copper tubing with the aluminum plates

The joining of the copper tubing with the aluminum plates is a major piece of the get together.
The congregation leads to the function of an evaporator and is completed when the copper tubing
is taken and stacked in the design of the barrette and precisely melding it onto aluminum plates.
The circuit occurs by taking a slug, or mandrel, and taking care of it through the copper cylinder
to amplify it and power it against within the opening in the plate
Pump Installation
The siphon is connected with fixtures to the framework and moored set up by help sections and
an establishment, worked to develop framework pressure and circle the working liquid. It is
catapulted along with the other forced air system auxiliary individuals and the covering or sheet
metal walled in area secures it. The walled in area is either bolted or blasted together to give the
inward parts adequate security.

3. Manufacturing process of plastic components of air conditioner

High-density polyethylene (HDPE) plastic: A long-chain polymer or plastic is high-thickness

polyethylene (HDPE). Polyethylene is the world's most normal sort of plastic and can be handled
in an assortment of ways, for example, with HDPE, to make it slim, adaptable, feathery or strong
and intense. For wood-plastic composites, for example, plastic timber, HDPE is for the most part
utilized.

The most mainstream

strategy for HDPE
creation is the creation of
wood-plastic
composites. With three major
warmed holding tanks, the
cycle starts. A
petroleum gas
subordinate called ethane is found in the essential tank. Ethane is warmed to simply over the
breaking point and filled a blending tank a short time later. Benzene comes from the other tank,
which serves to go about as a substance for ethane polymerization when joined with UV
radiation from overhead lights. . A progression of huge shallow board-like metal box are
siphoned with the synthetic. The substance is cooked at low warmth as opposed to being
permitted to cool to take into consideration the arrival of caught air and oxygen. The box channel
out from here into a progression of upstanding metal molds containing destroyed wood fibre.
The HDPE sheets can be conveyed to retail organizations whenever they are permitted to cool
for around eight hours.
Plastic mesh filters: are ordinarily introduced in the vast majority of the room's indoor or
window cooling frameworks. They're brisk to escape the machine. Wash altogether with water
and family dishes, washing the cleanser to eliminate the soil that has adhered to it. Leave to dry
and bring it back. These essential cleaning estimates help guarantee the effectiveness of the
gadget and hence spare energy, just as giving a cleaner air space to you.

Mesh Filter For Air Conditioner: otherwise called Air Filter, Air Conditioner Filter Pieces. Wire
work cooling channel material arrangement

1. White or dark nylon work made of PP filtration material.

2. with corrosive and basic protection from erosion.

3. Can be cleaned over and over, the nature of filtration isn't influenced.

Strong great protection from scraped spot, the first of the filaments. High temperature resilience,
protection from oxidation, protection from oil, protection from consumption, powerful frail
antacid corrosive, stable synthetic properties. There is a sure level of imperviousness to fire,
solid electrical protection and vibration-engrossing sound.
QUESTION 2

Assembly operations used to assemble the entire air conditioner

Refrigeration is utilized via forced air systems to cool indoor air, exploiting a noteworthy actual
law: it retains heat as a fluid changes to a gas (in a technique called stage transformation). By
driving exceptional substance mixes to dissipate and gather again and again in a shut
arrangement of curls, forced air systems misuse this component of stage change. Refrigerants
that have properties that permit them to modify at generally low temperatures are the mixes
included. Fans that ignore warm inside air these chilly, refrigerant-filled curls regularly
incorporate forced air systems. Central air conditioners really have a total arrangement of
channels worked to stream air to and from these serpentine, air-chilling curls. The refrigerant
inside retains heat as hot air disregards the cool low-pressure evaporator coils as it changes
from a fluid to a vaporous state. The climate control system needs to turn the refrigerant gas back
to a fluid again to continue cooling successfully. To do that, the gas is put under high tension by
a blower, a cycle that produces superfluous warmth. With the guide of a second assortment of
loops, called condenser coils, all the additional warmth gave by packing the gas is then emptied
to the outside.

Suggestions to improve the manufacturing process

Chilled water frameworks - The entire forced air system is mounted on the rooftop or behind
the structure in a chilled-water framework. It cools water to 4.4 and 7.2 degrees Celsius (40 and
45 degrees Fahrenheit). All through the house, the chilled water is then channelled and connected
to air controllers. This can be an adaptable gadget where in a customary climate control system,
the water pipes act like the evaporator loops.

Cooling tower innovation - In the entirety of the cooling frameworks we have referenced up
until this point, air is utilized to scatter heat from the blower loops. Rather a cooling tower is
utilized in certain enormous frameworks. The pinnacle creates a surge of cold water that course
through a warmth exchanger, cooling the hot condenser curls. The pinnacle shoots air into a
flood of water, permitting some of it to dissipate, and the vanishing cools the surge of water.
REFERENCES

1. https://home.howstuffworks.com/ac1.htm

2. Acker, W., Industrial Dehumidification: Water Vapour Load Calculations and System
Descriptions, HPAC, no. 3, 1999, pp. 49–59.

3. ASHRAE, ASHRAE Handbook 1996, HVAC Systems and Equipment, ASHRAE Inc.,
Atlanta, GA, 1996.

4. ASHRAE, ASHRAE Handbook 1997, Fundamentals, Atlanta, GA, 1997.

5.https://gmpua.com/CleanRoom/HVAC/Cooling/Handbook%20of%20Air
%20Conditioning%20and%20Refrigeration.pdf

6. ASHRAE, ASHRAE Standard 15-1994, Safety Code for Mechanical Refrigeration,

Atlanta, GA, 1998.

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