Name of Product: Air Cooler

Name of Manufacture: Symphony Limited, Ahmedabad, India.

Symphony Siesta 70 XL Powerful Desert Air Cooler:

Literature Review:
Classic book by Watt is an excellent qualitative review of the various
concepts, devices and systems, which had been in vogue by that time, though the
corresponding quantitative analysis was missing. The two papers by Mathur and Jain
presented mathematical model showing the performance of the air cooler fitted in a
room, are typical publications in this area in 70s and early 80s. Singh investigated the
dependence of tropical summer index (TSI) in a room cooled by air washer type air
cooler. Optimum values of the operating parameters viz packing factor, pad area, and
the airflow rate for which the mean daily TSI is minimum has been determined for a
typical set of a cooler, room and meteorological conditions. Singh, developed a
mathematical model characterizing optimization of the cooling performance of air
cooler, and defined two new conditions which determine the cooling capacity of this
cooler. Dowdy evaluated heat and mass transfer coefficient by conducting
experiments with the help of various types of cellulose pads thickness. Sodha analyzed
the cooling tower’s thermal performance which is fitted in the building in terms of
discomfort index for dry and warm climates. Singh, Tulsidasni, Swhney and Sodha in
series of 6 papers reported their work on optimization of coefficient of performance
(COP), cooling potential, thermal performance in building, recirculation effect on
cooled room and design evolution has been investigated in IEC (Indirect Evaporative
Cooling) system. Plasencia developed a new model which is based on transfer of heat
and mass for IEC; few simplifications were incorporated to make this model as user
friendly used for analysis of energy as well as adaption of system. Camargo et al
presented an operational concept for both type of cooling systems and generated
equations for mass and heat transfer between warm air and wetted media. Above
researches and mathematical models has been limited up to the conditioning of air
coming out of the coolers, and to increase the saturation efficiency or effectiveness of
cooler, however the use of cooled water stored in tank was not at all explored. This
gap of not using the coolness of cooler water has been identified as a research gap and
thus becomes the main objective of the present work. The coolness stored in tank
water can be utilized for mild refrigeration or to cool. As in present work it is suggested
that the cooler water can be utilized to cool the objects stored in the cooler tank.
AESTHETIC AND ERGONOMIC DESIGN CONSIDERATION
Description about Project:
1. Material selection as a competitive factor:
Three forces are affecting today’s enterprises; they are
the three Cs: Customers, Change and Competition (Hammer and Champy, 1993).
Marketing and competition deal directly with three factors Time, cost and
quality. The enterprise that could catch the market with a satisfactory product
or service and best price would catch a sale. Cost and quality are the most
important factors in the economics of companies. In this work evaluation of
competitive factors that affect air coolers is applied. The main competitive
factor that is pointed for such products is how long may be its age, besides
weight, nice shape finishing, manufacturing process and of course cost. Cost is
affected with all the factor the customer is ready to pay the extra cost for a life
product. In this work focusing on the best material to be selected for
manufacturing air coolers' windows out of three types of materials usually used.
Several tests are conducted to select the best material. These tests are Merit
index, corrosion tests and ANSYS.

2. Materials and Methods:

Air coolers are industrial products which are widely used in the
countries that suffers from high summer temperature. This product could be
produced using different types of material with good corrosion resistance; for
the function of this product is cooling using water pumps and fans. The main
part that suffers from its short life is the air cooler windows. The shape of the
air cooler's window. The technical specification for air cooler windows, taking
into consideration the three main materials used for fabricating them. These
materials are Aluminium, Galvanized steel and plastic.
Three materials are selected after visits to dependent
manufacturing companies for air cooler fabrication, which are (Eugene et.al.,
2007) Aluminium Alloy 3003 and Galvanized steel as samples from Al Hilal
company according to their used raw material; and Polypropylene from Al
nuaman company, these companies are related to the ministry of industry and
minerals in Iraq. Three samples for each material with different thicknesses are
chosen.
 1. Aluminium Alloy 3003
2. Galvanized steel
3. Polypropylene

4. Product Specifications:

Brand Symphony
Colour White
Item Dimensions LxWxH 50.5 x 61.8 x 111.5 Centimetres

Wattage 150 Watts

Material Plastic
Controls Type Knob
Standby power consumption 150 Watts

Form Factor Desert Cooler

Included Components 1 unit air cooler, 5 unit castor wheels
Item Weight 12.1 Kilograms

5. Product Details:
• Product Dimensions: 50.5 x 61.8 x 111.5 cm; 12.1 Kilograms
• Date First Available: 7 January 2020
• Manufacturer: Symphony Limited
• ASIN: B083KRRMX5
• Item model number: SIESTA 70 XL
• Country of Origin: India
• Manufacturer: Symphony Limited, Symphony Limited Symphony House, FP12-TP50
Bodakdev, Ahmedabad 380059
Phone: +91 79 6621 1111
• Packer: Symphony Limited Symphony House, FP12-TP50 Bodakdev, Ahmedabad 380059
Phone: +91 79 6621 1111
• Item Weight: 12 kg 100 g
• Item Dimensions (LxWxH): 50.5 x 61.8 x 111.5 Centimetres
• Net Quantity: 1 unit
• Included Components: 1 unit air cooler, 5-unit castor wheels
• Generic Name: SIESTA 70 XL
Aesthetic consideration in designing of ‘Air Cooler’

• Materials:
1. Aluminium Alloy:
Aluminium alloy3003 is in the wrought aluminium-manganese group. This alloy can
be worked on cold to create tempers that have greater strength with lesser ductility. Similar to other
Al-Mn alloys, 3003 is a general-purpose alloy that has reasonable strength, respectable workability,
besides good resistance to corrosion. This alloy is generally rolled and extruded and not forged. For
being a wrought alloy, it will not be used in casting process, but it has good weld ability. Sheet metal
applications are its main uses especially for roofing, and siding. shows its physical properties.

Aluminium Alloy 3003 Properties:

1. Density 2.7
2. Thermal Conductivity 237
3. Expansion Coefficient 23.1
4. Melting Point 660

2. Galvanized steel:
Hot-galvanization is the process of covering iron and steel with a film of zinc by dipping
a metal in a bath of melted Zn at a temperature of about 840 °F (449 °C). Galvanized steel is commonly
used in corrosion resistance applications products without bearing the cost of stainless steel.
Galvanized steel could be recognized through the crystallization designing on a surface which
frequently termed "spangle”. The Galvanized steel is proper for high temperature uses up to 392 °F
/ 200 °C and could be welded. Electro galvanized steel plates are regularly used in the manufacturing
of automotive in order to improve the corrosion routine of external body panels. This is totally
different process which requires attaining minor layer thicknesses of Zn. Similar to other corrosion
protection methods, galvanizing shields steel by substitute as a barrier between the steel and the
atmosphere surrounding. Its physical properties.
 Galvanized steel physical properties:

1. Density 8.22
2. Thermal Conductivity 40
3. Expansion Coefficient 13.9
4. Melting Point 1355

3. Polypropylene:
Polypropylene PP is a thermoplastic polymer. This polymer is used in an extensive
diversity of applications which might be packaging and labelling, textiles such as ropes, thermal
underwear and carpets. Other applications are for recyclable containers of different styles,
laboratory kits, loudspeakers, motorized machine rise, in addition to polymer. Additionally, polymer
prepared depending the monomer propylene is rough; oddly resist numerous chemical solvents
besides bases and acids. The physical properties of polypropylene.

The physical properties of polypropylene:

1. Density 0.964
2. Thermal Conductivity 0.16
3. Expansion Coefficient 13
4. Melting Point 160

• Shape:
1. Symphony Sumo 75 XL Powerful Desert Air Cooler
2. Crompton Optimus 65-Litre Desert
3. Orient Electric Smart Cooler Personal Air Cooler
4. Bajaj 54-litres Window Air Cooler
5. Symphony Siesta 70 XL Powerful Desert Air Cooler
• Proportion:

Symphony Siesta 70 XL Powerful Desert Air Cooler:

The Symphony Siesta 70 XL Powerful Desert Air Cooler lets you survive the
rising temperature of India. The high-performance desert air cooler for home is
designed to be used in hot and dry regions where the average temperature goes
up to 50 degrees. This symphony air cooler is designed to use less electric power
as it runs on an operating cost of a fan. The water pump of the cooler works on
dura-pump technology which ensures its longevity.

• Continuity:

A method of providing goods or services to consumers that relies on direct

marketing and continues into perpetuity.

• Contrast:
Contrast is a distinction between the adjacent elements of the product which
have clearly different characteristics and functions.

Material Contrast:

Body & other accessories mainly made of Polypropylene material with base
soleplate of coated aluminium alloy material.
• Variety:
The number of variants in a family of products with similar characteristics,
usually referred to as brands or models of the product.

Symphony Sumo 75 XL Powerful Desert Air:

Symphony 30 Litres Tower Air Cooler:

Kenstar Alta 15 Litres Tower Air Cooler

Symphony Hi Cool:

• Colour:
It is in White colour.
• Feature:
Cool Flow Dispenser:
It is equipped with a cool flow dispenser which distributes water evenly for better cooling.

Dura-pump Technology:
The water pump of the cooler works on dura-pump technology which ensures its longevity.

Low Power Consumption:

This symphony air cooler is designed to use less electric power as it runs on an operating cost
of a fan.
High-efficiency Honeycomb Cooling Pads:
The cooler is equipped with honeycomb cooling pads. Honeycomb cooling pads can retain
water just like a hive contains honey. So, when the hot air is pulled through the pads, it is cooled
down faster due to the water retained in the chambers of the cooling media.

Ergonomic consideration in designing of ‘Air Cooler’

Parts:
The air cooler's window.

Cooling Pads:

i.Aspen cooling pads:

Aspen cooling pads are made up of synthetic fiber and wood, and looks like a grass. Aspen cooling
pads are cheap and economical, this is the reason Aspen cooling pads coolers are cheap but it requires high
maintenance and it is less durable material. Aspen pads are less effective than the cellulose pads.
E.g.: Aspen pad

ii. Cellulose pads:

It is made up of cellulose material and also called honeycomb pads, it is very effective in cooling and
require high maintenance or cleaning. This is high durable material and more effective than the aspen
cooling pads. In desert air coolers cellulose pads are used because of their cooling potency of air in large
scale.

E.g.: Honeycomb pad.

B. Motor, Pump, Fan:

Other parts include the selection of motor driven exhaust fan to drive the flow of air into the room to
be cooled. A pump is used for water carrying from tank of cooler to top distribution systems, where it is
distributed to the three different pads.

E.g.: Fan, Motor, Pump

a) Motor b) Fan c) Pump

C. Refrigeration box:
The box we used in this project is made up of G.I. Sheet which is in rectangle shape, which is to be
kept inside the cooler tank for that purpose it has been fully insulated, so that we kept it inside the water.
Inside the box we have fitted two bulbs are fitted of 5W & 10W and also a sensor is fitted for taking the
reading of temperature inside the box. The box is having the sizes (Length=30cm, Breadth=35cm,
Height=10cm).

Relations Between User and Working Environment:

Unlike air conditioners, air coolers use water as their refrigerant
instead of the CFC and HFC. Thus, it is safer not only to the environment but also
to human health. This natural air cooling is proven to be effective even though it
does not rely on harmful chemical coolants. When you turn on the cooler, the
mould in the device could be spread through the process of blowing the air out
into the ducts. This can certainly cause problems, whether or not people are
allergic to mould and mildew spores.
It will work everywhere. All you need is to keep door and windows open for
ventilation while using. So that effective cooling can generate. I'm using it in Erode,
Tamilnadu since march. It's awesome only if you provide ventilation or else it will
bring humidity and cooling effect won't be great. I understand the ventilation
concept only after few days. Since it's a desert cooler it's must to keep door and
windows open
Display and Control:
Air cooling is the most energy-efficient cooling technology available. Operating
costs for an air cooler are 1/10th of a traditional air conditioner. A 2.2-ton split air
conditioning unit can consume 2200 watts an hour. A Symphony air cooler consumes
nearly the same amount of energy as a standard ceiling fan. Symphony air cooling
units require energy in the range of 105 watts/hr to 255 watts/hr.
Although the energy consumption of a ceiling fan and air cooler is similar, the
cooling effect is considerably different. Air coolers can cover a larger area, actually
cool the air, and work noiselessly.
A power consumption of just 155 W, the cooler helps to cool a large area of
110 mt3. The powerful 16-inch fan helps in uniform air circulation while the cool
flow dispenser helps to channelize water distribution effectively for a superior
cooling experience. Apart from keeping room temperatures under control, the
cooler also comes with an I-Pure technology that ensures that no sort of allergens
and bacteria are present in the air of your room to give you healthy and breathable
air.

Layout and Design: