Professional Documents
Culture Documents
ACKNOWLEDGEMENT
The final year project entitled Design and Fabrication of Smart Portable Air
conditioner was successfully finished with the of everyone who participated and
supported me from the beginning to the end of this project. In this opportunity, I
would like to thank on my family and my friends because of their understanding to all
my effort on this project.
A special thanks I given to Mr Abdul Aziz Bin Ahmad and Mr Khir Bin Harun
as my supervisor and co supervisor who were guided and giving full attention to
finish this project. All their suggestions and ideas were very brilliant which very
helpful to apply in this project. The constant support from them leads this project to be
succesull.
Beside that, to a very special person Mr Ahmad Zaini Bin Idris from Giat Mara
Teluk Intan that I would to thanks because of giving permission to use his workshop
and helping on finding the components and material for this project.
Finally, I would like to express my full appreciation to all my comrades from
Bachelor Mechanical Semester 7 on giving support and sharing ideas. Without them,
this project may not be established.
LIST OF TABLES
LIST OF FIGURES
ABSTRACT
CONTENTS
LIST OF TABLES
LIST OF FIGURES
ABSTRACT
CHAPTER 1: INTRODUCTION ............................................................................................ 10
1.1.
1.2.
1.3.
Objective .................................................................................................................... 12
1.4.
5.2
5.3
5.4
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
5.5
5.6
5.7
Motion Sensor............................................................................................................ 25
5.8
5.9
4.2.1
4.2.2
4.2.3
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
Internet ............................................................................................................... 34
4.2.6
Design Analysis.................................................................................................. 34
4.2.7
Visit .................................................................................................................... 34
5.2
4.2.1
Manufacturing .................................................................................................... 35
4.2.2
RESULT .................................................................................................................... 37
4.2.1
FLEXIBLE HOSE.............................................................................................. 38
4.2.2
TESTING ........................................................................................................... 38
5.2
DISCUSSION ............................................................................................................ 41
4.2.1
4.2.2
4.2.3
CONCLUSION ......................................................................................................... 45
5.2
REFERENCES ......................................................................................................................... 47
APPENDIX .............................................................................................................................. 48
9
CHAPTER 1: INTRODUCTION
1.1. Portable Air Conditioning system
Portable air conditioner is an innovation product originally from standard air
conditioner that is limited to be used in room or inside building . Then, it is design to
make it easier to move from one place to another. This product is design looks like a
decoration tree which people mostly use it as an decoration in outdoor event such as
wedding and talk.
As we all notice that Malaysia has a tropical rainforest climate due to its
proximity to the equator. It is hot and humid country all year round, with an average
temperature of 27 C (80.6 F) and almost no variability in the yearly temperature.
Mostly malaysians are finding a way to get comfort escpecially during day event. This
portable air conditioner can help them to produce comfortable environment in the hot
day. Besides, they do not have to depend to conventional fan that still producing warm
air but this portable will give cold air same as normal air conditioner that in close
room.
This portable air conditioner is equiped with photo sensor that can sense the
existence of people in front of it and it will automatically switch off if there is no
people and it will turn on back if it detect people crossing or standing in front of it.
This will make people easier rather than switching on or off manually especially in the
busy event. It is also economize the electricity when the usage is continously without
people using it which lead to waste the energy.
The present of air conditioner is difficult to install especially to fit in outdoor
environment. This product is design with wheel which make it easier to move and
install. With the simplest installation procedure, anyone can easily install the air
conditioner to wherever they are desired.
10
11
1.3. Objective
1. To develop a new type of portable air conditioning system which is
easy to setup and bring everywhere rather than conventional air
conditioner.
12
13
The part of the system in the room, on the left, pulls airfirst over a cool surface
and then over a warming surface. The part of the system on the right recirculates the
cooling fluid. The fluid passes from the reservoir through a valve B into the lower
pressure within the cooling unit in the room. There the liquid boils, removing heat
from the air. The boiling point is fixed by the constant pressure set by valve A. The
vapour is then compressed and condensed back into a liquid which collects in the
reservoir ready for another cycle.
14
Air conditioning has in the past been used where the climate is too hot for
comfort. Cooling will increase the relative humidity of the air, so humidification is not
usually built into these systems. If it is necessary, the usual method is to inject steam
from electrically boiled water. That is all there is to the part of the system in the room,
which is sketched on the left in figure The bit that is more difficult to understand, or at
least unfamiliar to most people, is how the cooling fluid is produced and controlled.
That is the part on the right of the diagram.
The cooling fluid used to be a chlorofluorocarbon compound, and often still is,
though they all more or less ravage the earth's ozone layer. The essential
characteristics of these fluids is that they have quite a low boiling point at atmospheric
pressure and that they can stay in the pipes for a long time without decomposing either
themselves or the pipes. Finally they need to have some lubricating ability, or the
ability to carry a lubricant, because the fluid has to be compressed and pumped round
the system. This rare set of necessary properties has proved difficult to combine with
friendliness to the earth's atmosphere. The liquid is let into the cooling unit through a
valve marked B on the diagram. It evaporates while it passes through the pipe, taking
heat from the air just as water evaporating from a towel laid on your fevered brow
cools you when on holiday in the Mediterranean.
The temperature in the cooling coil depends partly on the amount of fluid let
in by the valve, which is controlled by the thermostat or the humidistat. But now
comes a crucial difference from your Mediterranean experience: the minimum
temperature at the cold surface can be fixed by controlling the pressure in the cooling
coil, with the valve marked A on the diagram. The boiling point of any liquid depends
on the pressure. One could use water in the cooling coil, if the pressure is kept low
enough. At 1000 Pa pressure, which seems a lot but is just 1% of atmospheric
pressure, water boils at 7 degrees. It isn't used in cooling coils of this evaporative type
because it has practical disadvantages.
15
The reason for wanting to limit the minimum temperature is to stop ice clogging the
air passage. There are clever systems which notice when ice has formed and hold a
melting pause, but that adds to the cost. The pressure controller is therefore set to
make the cooling fluid boil at the lowest temperature that is likely to be needed to
control the humidity, but always over zero degrees. The temperature needed for
cooling is nearly always higher than that needed for dehumidification so it is the RH
setting that is decisive.
This brings me to the first point that conservators need to understand: it is expensive to
produce air at a dew point below about 4 degrees in this type of equipment. This
dewpoint corresponds to 50% RH at 15C. This sort of air conditioning is entirely
suitable for keeping people comfortable but it is not good for specialised stores, for
films or for furs, for example, where one needs a temperature below 15 degrees. Such
equipment is, however, often used for such places. A better solution is to use an
absorption dehumidifier, which will be described in a later article.
Now back to the main story: The vapour that emerges through the pressure controller
is gathered up by a compressor. The compression also heats the gas, as will be
understood by anyone who has pumped up a cycle tyre. The hot gas is then led away
from the room, to be cooled down. This is often done on the roof or in a small
enclosure which vibrates to the roar of the fan blowing air over the fins of a condenser.
The cooled, now liquid coolant is piped back to the reservoir, ready for its next tour
through the room air conditioner.
The entire process described above is inefficient and uses electricity, which is itself
produced by inefficient conversion of heat energy. Such systems are therefore
confined to small places where the inefficiency is compensated by the generally high
reliability and freedom from maintenance.
16
17
Use these systems for applications where several spaces with uniform loads
will be served by a single apparatus and where precision control of the environment is
required. Cooling coils can be direct expansion or chilled water. Select air cooled or
evaporative condensers, cooling towers, and ground-loop systems based on life cycle
economics considering operating efficiencies and maintenance costs associated with
outdoor design conditions and environment, e.g., high ambient temperatures and dusty
conditions could adversely impact the operation of air cooled condensers. Consider
temperature rise of chilled water supply when selecting chilled water coils, especially
for applications requiring precision humidity control.
18
4.2.2
These systems should generally be limited to loads less than 100 tons. Unitary
systems are packaged in self-contained or split configurations. Self-contained units
incorporate components for cooling or cooling and heating in one apparatus.
Thermostatic expansion valves are preferred over capillary tubes and orifices for
refrigerant control when available as a manufacturer's option since expansion valves
provide better superheat control over a wide range of operating conditions. Split
systems may include the following configurations:
a) Direct expansion coil and supply fan combined with a remote
These systems generally have lower first cost than central systems but may
have higher life cycle costs. If part load operation is anticipated for a majority of
equipment operating life, consider multiple unitary equipment for superior operating
efficiencies and added reliability. Refer to ASHRAE Handbook, Equipment for size
and selection criteria.
4.2.3
These units are self-contained units serving only one space. These units are
typically referred to as window or through-the-wall type air conditioners. Rooms
served by these units should have a separate HVAC unit to provide ventilation air for a
group of rooms. Use them when they are life cycle cost effective, and in accordance
with MIL-HDBK-1190. Refer to ASHRAE Equipment Handbook.
19
4.2.4
Built-up Systems.
The more common of the two types of central air conditioners, split system air
conditioners have the compressor / condenser housed in a unit outdoors and the
evaporator indoors. The primary benefit of split system air conditioners is that they
keep the noisy part outside. Split system air conditioners connect into your existing
ductwork, cooling your home evenly and quietly
20
Figure 2 - Evaporator
Figure 3 Condensor
21
evaporator
-a
pump
that
pressurizes
the
refrigerant
Figure 5 - Compressor
22
23
24
are
based
coupling, capacitive
and fiber
optic transmission. Radar intrusion sensors have the lowest rate of false alarms.
Motion sensor is a device for motion detection. That is, it is a device that
contains a physical mechanism or electronic sensor that quantifiesmotion that can be
either integrated with or connected to other devices that alert the user of the presence
of a moving object within the field of view. They form a vital component of
comprehensive security systems, for both homes and businesses.
Motion sensor that transforms the detection of motion into an electric signal.
This can be achieved by measuring optical changes in the field of view. Most motion
detectors can detect up to 15 25 meters (5080ft).
25
26
Tree signatures a support and strong bond with human. Tree trunk is like our
love of each other who is giving a solid supports to all the people to sit or stand under
it. When hot sun or heavy rain, the tree leaves will cover us and let us to have faith
facing challenge and continue the life journey. It symbolize a lovely meaning for
couple to use tree as their wedding decoration.
27
Tree can be decorated in various way and present in different theme such as
Winter Wonderland with white cherry blossom tree, Oriental with pink cherry blossom
tree, Secret Garden with green trees, etc.Tree can be transformed in various design in a
wedding such as table centerpiece, walkway, entrance, wishing tree to hang message.
Every tree branches used in decoration are real and taken from forest.
If you are an eco-friendly supporter or go green supporter, be mindful to choose this
decoration idea.
28
Most sales in those first years consisted of stock orders from the wholesaler.
Few end user orders were placed. With excess inventory in stock, wholesaler reorders
were scarce. It wasnt long before some adjustments needed to be made to the
distribution channel to jump start sales. The decision was made to establish a network
of direct-sales outlets that specialized in portable air conditioning and sold directly to
the marketplace.
This proved to be much more successful than traditional wholesaledistribution. Sales to the end user improved, but it was good timing that proved to be
the most influential element to the success of the industry. That timing relates to the
explosion of the minicomputer that began in the mid 1980s, during this same period.
4.2.1
Enter the portable air conditioner (spot cooler as it has since been dubbed) as a
dedicated
a/c
system
for
many
of
these
smaller
computer
rooms.
Use in the computer room created visibility and really previewed the products
problem-solving capabilities. Other applications for people and process cooling were
soon extrapolated from this exposure. But not all of these new applications had the
year-round
requirements
of
the
dedicated
computer
cooler.
29
RENTAL MARKET
Portable air conditioning providers started setting up shop across the country.
By the mid 1990s, nearly all major and most secondary cities had a supplier in the
area.
air
conditioning
was
becoming
mainstream.
Portable air conditioners generally refer to units on wheels that can fit through
standard interior doorways. As such, they can be deployed anywhere within a
commercial building. This tends to limit portable air conditioners to about 5 tons in
capacity. Mobile air conditioners are units mounted on trailers or skids, which can be
hauled or trucked to a site. Mobile units can be anything from a 10-ton trailer-mounted
unit,
to
1,000-ton
chillers
on
flat
beds.
As the portable air conditioning market was expanding, the mobile air
conditioning market was also growing. American business was becoming increasingly
reliant upon instant access to cooling for any number of cooling problems, large or
small. While portables were ideal for isolated cooling issues within a commercial or
institutional building, mobile units could be dispatched to provide cooling for entire
buildings or structures. Often, both were used for providing the cooling solution.
30
4.2.3
CONTRACTOR SOLUTIONS
Air conditioning and mechanical contractors became the biggest advocates for
portable air conditioners. Uses vary depending on conditions. Most contractors rent
equipment, as the larger portable a/c providers will inventory all types and models
locally,
making
renting
viable
option.
Some contractors also maintain a small fleet of the more popular models for
quick deployment. Among the most popular applications are rentals for interim
cooling when replacing, repairing, or servicing server or computer room air
conditioning units. Many contractors also specify portables as dedicated cooling units
for
variety
of
long-term
cooling
needs.
But the end user also found spot cooling to be the ideal way to provide
equipment protection as well as worker comfort. Customers in industries across the
entire spectrum have utilized portables in the office, warehouse, production area, or on
the construction site. Its safe to say there arent many, if any, types of business that
havent
used
portables
to
solve
heat-related
issues.
service
companies
also
utilize
portables
regularly.
When something solves your problem, you come to rely on it. Use it often
enough, and it is no longer considered a luxury, but a necessity. Take it away, and you
experience hardship. You would find this to be true if you no longer had access to
your
cell
phone,
laptop,
or
the
Internet.
Add portable air conditioning to this list. It has evolved to the point where it is
no longer just a curiosity; from our standpoint, it ranks in importance right up there
with all of our other modern conveniences.
31
CHAPTER 3 METHODOLOGY
Methodology can properly refer to the theoretical analysis of the methods
appropriate to a field of study or to the body of methods and principles particular to a
branch of knowledge(www.answers.com/topic/methodology). In this chapter, it talks
about the methods use to gather information in order to finish the research. It was
involve the process flow of every step in archive the objective of this project. There
are many methods use in this project such as internet references, interviewing lecturers
and technicians and the most important is group discussion.
METHODOLOGY
Validity of Theoretical
Theoretical
Analysis
Analysis
Manufacturing
Group Discussion
Internet
Product Testing
Design Analysis
Visit
32
Group Discussion
There 2 more students with same that are doing research on the same type of
project which is air conditioner but 2 of them are doing in different part. So, we are
also gather together to discuss about this project,. By discussing among the group, we
help each other to solve problem. By doing group discussion we manage to came out
with a few solution of the problem statement. These are the discussion that we were
discussed:
4.2.2
To complete the requirement of this final year project, I need to choose three topic to
be our own project and we have come out with few topics which need further
discussion to select which topic are the suitable. The 3 topics are compressor study,
refrigerant study and I have finally decided to choose new generation of portable air
conditioner as the topic of my final year project. We have concluded that they will do
their test also in my project. This is because the new generation of portable air
conditioner has full fill all the final year project requirement that are application,
realistic, modification and innovation.
4.2.3
At first stage, we have discussed the time line of this project. After the topic
was selected, we were writing the topic proposal for one week. We had divided into
four phases of the time frame. For the first phases, we had searched as many as
information that could for about two month. The second phases are we start writing
the progress report. The progress report included introduction, literature review and
methodology. We spent time for this phase about two months. Phase three and four
will be next semester which the manufacturing process and result.
33
4.2.4
In our project, i have found few risks that can jeopardise my result. So i discuss
with them. The risks that we face are the process of manufacturing needs highly skill.
Manufacturing the portable air conditioner involve process such as safety, assembling,
and painting. If there are mistake happen, the functionality of this air conditioner will
be reduce. Other than that, to develop the portable air conditioner we need to spend a
lot of money to make this project success. So we have set up a few limitations on our
project to get good result.
4.2.5
Internet
4.2.6
Design Analysis
After gather all information, I need to design portable air conditioner. At the
early stage I only do drawing and sketching on the paper. I have drawn as many
designs that possible. After complete the drawing, we have chosen one drawing that is
the best design and the latest. The next step is to get the measurement of the design
that can be suit into air conditioning system.
4.2.7
Visit
I have been set up to visit Giat Mara Teluk Intan which they have won
innovation competition among Giat Mara Malaysia with innovation airconditioner
product. The purpose to come here is to get some advice about the air conditioning
system from their teacher and use some of their facilities to manufact the air
conditioner due to Unikl Miat is not have enough tools and equipment especially for
normal air conditioner.
34
Manufacturing
Before starts the manufaturing process, there are some materials are needed to
prepared to manufact this smart portable air conditioner which are:1. Hose
2. Fiber
3. Resin
4. Wheels
5. Paint
6. Decoration stuff
7. Refrigerant (R22 and Co2)
Beside that, the list equipments needed on this project are:1. spanar set
2. solder and welder
3. filler
4. brush
5. thermometer
6. drill
7. vacuum pump
8. pressure gauge
35
In the manufacturing process, I have chosen all the suitable components to use
in the system then assemble all of it to be a air conditioning system. The decoration of
the portable airconditioner will be making as housing of the conditioner. There are
severeal steps in manufacturing process which are:1. Finding unused components whether already damaged or still working
but it should be repairable. The main components should find is
compressor and blower.
2. The next step is repair the components. There are several steps of
repairing process such as placing parts, welding, soldering and wiring.
The problem that usually occur on the unused compressor and blower is
leakage at the pipes.
3. The air conditioner is design raftly and it should be fitted wih the
components then do the scaling to get the exact size of the air
conditioner body.
4. Then it is proceed with molding the the air conditoner body by using
composite materials. The materials used to build the air conditioner
body are fiber, resin and catalyst.
5. After the bulding the body is finished, it is proceed with the painting
process. The body is paint by using varnish to make it look like a real
tree. then it will add some decorations like leaf.
6. The last stage of the process is testing. The product is tested by
assembling all the components and connect with the power source.
4.2.2
Product Testing
After the product has been finalized, this product will be tested in Unikl Miat
workshop. it will test the portable air conditioner to use inside the workshop whether it
can operate or not. If not, some modification should do to make sure it functions
properly.
36
37
4.2.1
FLEXIBLE HOSE
Flexible wire is use on this smart portable air conditioner system because it is
easier to move the air conditioner rather than using cooper tube. The flexible hose is
made of rubber and it is usually uses in car air conditioning system. For this this
system, I have been using this hose for 10ft but we can increase the length of the hose
if need.
TESTING
The testing of this smart portable air conditioner has been tested at two type of
place which are in small confined place ad outdoor. The thermometer has been used to
measure the temperature. It was put 1meter in front of the air conditioner direct to the
air out. This test is done to measure the effectiveness of the air conditioner to cool the
environment.
38
Time (Minute)
Temperature (Degree
Temperature (Degree
Celcius) atoutdoor in
open air
34
36
32
36
30
35
28
33
10
25
32
20
25
32
As we can see from the result, the air conditioner is easier to cool in the small
confined room because of the closed area. But in the open area, this is very difficult to
cool because of the some reason which are it was placed in open air and the blower
was not strong for cooled air to reach longer distance. The blower should be strong as
a big fan to cool larger area.
39
Distance (feet)
0
25
0.5
25
1
27
1.5
28
2
29
2.5
30
3
40
5.2 DISCUSSION
4.2.1
The old type of window air conditioner is choose because of the size of the
component is small and easy to be suited to the design which is tree. The component is
use as blower of the smart portable air conditioner.
Then, I found a damaged compressor but it still repairable because of the motor
is still working properly.
41
For the repaired, I have been doing repairing on the compressor and the
blower. For the blower, there are some leakage found on the copper pipe but the I have
soldered all the leakage. To make sure there is no leakage, the pipe have been tested
by using water and soap.
On the compressor part, there are some problem on the wiring which is the
wired broken and it may caused by rat or wire decayed. New set of wiring has been
installed on this compressor.
In the other side, by using the repaired components of the air conditing system
has been reducing the cost of making the project which the price of the components
were sold in low price.
In market view, we can just selling this product cheaper in the market place
compared to other portable air conditioners that already established in the market.
Beside that, we might able to recycle the broken components instead of the
components become waste.
42
4.2.2
DECORATION DESIGN
The smart portable air conditioner has been design to look like a decoration
tree. It has been made from composite and painted in brown which look like a real
tree. The tree is suitable to be used as a decoration.
So that, there is no needs a larger area to place air conditioner especially during
event. We can also place the smart portable air conditioner directly to cool the area.
43
4.2.3
EASY TO SETUP
The smart portable air conditioner has been equipped with wheels which make
it easier to move rather than lift it up with the heavy compressor. The weight of their
air conditioner blower also has been reduced due to the body was ade of composite
which is light weight and strong.
Beside that, it has been designed with plug and on concept which we just
needed to plug the power source to switch on this system. Other than that, there are
just a few steps to assemble the system. It is also could make us faster to install the air
conditioner system rather than conventional air conditioner system.
44
45
46
REFERENCES
i.
Energy Solution,buildinggreen.com,
http://www2.buildinggreen.com/blogs/chilling-out-air-conditioners
ii.
iii.
iv.
v.
vi.
vii.
viii.
http://www.answers.com/topic/methodology
47
APPENDIX
48
49
50
51