Shane Michael A.

Bacalso Assignment #4
BSME-4

MANUFACTURING OF REFRIGERATORS

A refrigerator is an open system that dispels heat from a closed space to a warmer area,
usually a kitchen or another room. By dispelling the heat from this area, it decreases
in temperature, allowing food and other items to remain at a cool temperature. Refrigerators
appear to violate the Second Law of Thermodynamics, but the key reason they do not is
because of the work needed as input to the system. They are essentially heat pumps, but work
to cool a region instead of heat it. Refrigerators today consist of several basic components: the
exterior cabinet and door, the inner cabinet or liner, the insulation inserted between the two,
the cooling system, the refrigerant, and the fixtures. The cabinet and door are made of
aluminum or steel sheet metal that is sometimes prepainted. The metal is generally purchased
in a coil that is either fed directly into the manufacturing process or cut to size and fed sheet by
sheet. The inner cabinet is made of sheet metal, like the outer cabinet, or of plastic. The
insulation that fills the gap between the inner and outer cabinets consists of fiberglass or
polyfoam. The components of the cooling system (compressor, condenser, coils, fins) are made
of aluminum, copper, or an alloy. The tubing is usually copper, because of that metal's ductility
—its ability to bend without breaking. Freon remains the most commonly used refrigerant, and
almost all of the large interior fixtures (door and cabinet liners) are made from vacuum-formed
plastic; smaller fixtures (butter compartments, egg trays, salad crispers) are purchased as small
plastic blanks or in pre-formed pieces. Refrigerators appear to violate the Second Law of
Thermodynamics, but the key reason they do not is because of the work needed as input to the
system. They are essentially heat pumps, but work to cool a region instead of heat it.

Manufacturing Process Includes:

Outer cabinet and door
1. Pieces of sheet metal are either welded or clinched together. Clinching is a process closely
resembling stapling in that the two pieces are crimped together under pressure, though no
additional pieces such as staples are added. If the part of the cabinet is to be visible, it will be
welded and ground down to appear as one piece. The extent to which the welding process is
automated depends on the company and the number of refrigerators being produced.
2. If the sheet metal was not purchased in precoated form, it is now painted. Some
manufacturers use spray equipment to lay a uniform coat of paint on the metal. Others dip the
parts in a paint/solvent mixture before heating them to bake the paint onto the surface.
Inner cabinet
3. The inner cabinet is sometimes made from sheet metal very similar to the outer shell. Any
seams are caulked to improve insulation and looks. Some manufacturers and some models use
plastic for inner liners; for example, the inner door is almost exclusively made from plastic
today. The plastic liners are vacuum formed. In this process, a thick piece of plastic slightly
larger than the finished part has its outer edges clamped and is then heated. The hot plastic is
next pulled by vacuum into a mold and cooled. After trimming, the resulting part is ready for
assembly.
4. The inner cabinet is inserted into the outer cabinet, and the two are snapped together before
the fixtures are inserted. Some tubes and wires are run through the gap between the two
before it is filled with insulation. A dispensing device (sometimes robotically operated,
sometimes a manually operated long 'gun') inserts foam between the walls. When heated in an
oven, this foam expands to add rigidity and insulation to the cabinet. A similar process is used
for the doors.
Cooling system
5. The refrigeration components are attached to the cabinet using screws and clips. The tubing
is soldered together, and a protective coating is sprayed on the joints. The order of this
assembly varies between manufacturers and models. The copper tubing from which the coils
(condensers and evaporators) have separately been cut, bent, and soldered is then attached to
the refrigerator as a unit.
6. The seal on the refrigerator door is created by means of magnet laden gaskets that are
attached to the doors with screws. Handles and hinges are also screwed onto the door before
its hinges are screwed onto the cabinet. Some adjustment is allowed for proper operation of
the door.
Testing and adding accessories
7. Most manufacturers mix testing with manufacturing from this point on. The unit is leak
tested with nitrogen (a safe gas that makes up about 79 percent of the air); if it passes, it is
charged with refrigerant and subjected to further testing. Next, the accessories (shelves,
crispers, ice trays, etc.) are added and taped down for shipping. The unit is given a final look
and then packaged for shipping.
 Pieces of sheet
Sheet metal is
metal are wielded Seams are caulked
painted
or clinched

Refrigeration
Inner cabinet is Seal on the
components are
insterted into the refrigerator door is
attached to the
outer cabinet created
cabinet

Mix Testing

The existing health and safety practices includes metal components that are rejected
are sold to metal recycling companies. Plastic components are ground into small pieces and
either reused as raw material or returned to the vendor for reuse. If a unit is rejected after it
has been charged, the refrigerant is drained by special equipment and reused. As mentioned
above, all subassemblies of tubing that will contain refrigerant are pressure-tested with
nitrogen, which will reveal any flaws in the tubing and in the soldering that joins it. The entire
unit is also leak-tested prior to charging with freon. Once charged, the unit is tested as a whole
to ensure that it is capable of reaching design temperatures including those necessary during
the defrost cycle. The unit is operated with sensors inside that determine the temperature
changes over time. Sometimes the refrigerant pressures are also measured. The unit is then
subjected to a final 'sniff test by a machine that detects refrigerant to ensure that no leaks have
developed during testing.
 MANUFACTURING OF NOLAN HELMETS

Nolan Helmets is an Italian motorcycle helmet firm founded in 1972 by Lander Nocchi,
an entrepreneur in the motorcycle and car accessory sectors.Nolan manufactures all
components to their helmets in-house. Nolan also manufactures the X-Lite helmet brand, as
well as the Grex value line of helmets for new riders. The raw materials in a Nolan Helmet
includes a hard outer shell which is usually made of hard polycarbonate plastics or are other
man-made fibers such as Kevlar or carbon fibre, the protective inner shell which is made of
expanded polystyrene or EPS as it is commonly known, the removal soft lining that keeps the
face and neck protected against the hard surface of the EPS which are usually made of
hypoallergenic materials to prevent any allergic reactions that you may have against sweat and
dust, the protective padding which is made of soft sponge or shock absorbing composite
materials that are great at keeping your comfortable on long rides as well as protecting the
facial bones in case of an accident, the strapping mechanism, the vents which allows a good air
flow from the front to the back, and finally the visors which are designed in such a manner that
it resists normal wear and tear of an average daily ride for up to years.
For the process in manufacturing Nolan helmets first is the making of the EPS helmet
liner. EPS is delivered in a big container filled with tiny little tube-shaped bits — the
polystyrene The polystyrene is then “blown” or expanded at the manufacturing facility to
become the EPS that protects our noggins. EPS is manufactured in different densities and
combined together in a helmet liner in the molding process. Next step is making a
polycarbonate helmet shell. In general, a polycarbonate helmet shell will be heavier than a
composite shell. But a polycarbonate shell can also take quite a beating. Next is sanding, paint
preparation, decals and painting. Once the helmet shells are prepared, they either go directly
into the automated paint booth or to the decal room. The decals are designed by artists on a
computer and printed on a single sheet. The decal is removed from the backing. Once the
helmets are painted and/or the decals are applied, they are sent through the automated clear
coat booth, where the excellent Nolan “Hi-Brite” clear coat finish is applied. Lastly is the
packing and shipping. In the final assembly area, each helmet is inspected once again and the
final parts are installed for the liner, chin guard and vent covers. The protective decals are also
installed and the helmet is wrapped, packed and put in a box with the manual and hang tags,
ready for shipment to your dealer and eventually on to your head.
BLOCK DIAGRAM:

Making the Making a

EPS Helmet Polycarbonate Sanding
Liner Helmet Shell

Paint
Decals Painting
Preparation

Final Assembly Packing Shipping

Personal protective equipment (PPE) means all equipment which is intended to be worn
or held by people at work and which protects them against one or more risks to their health
and safety, and any addition or accessory designed to meet that objective. All PPE should be
used as a last resort to reduce the risk taking into consideration that the risk will not be
eliminated.
Safety helmets are one of the most frequently used forms of PPE. Safety helmets will protect
the user’s head against:

 impact from objects falling from above, by resisting and deflecting blows to the head.
 hitting fixed dangerous objects at the workplace,
 lateral forces - depending on the type of hard hat selected. Traditional hard hats are not
designed to protect users from impacts to the front, side or back of the head.
 open flame, molten metals splash, electric shock, high temperature – depending on the
additional protective properties of the hard hat selected, e.g. a basic, standard safety
helmet does not protect against an electric shock.