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.