DESIGN AND FABRICATION OF VERTICAL AIRCONDITIONER WITH 360 VERTICAL AIR FLOW

PROJECT REPORT
Submitted by
A.VIJAY SHANKAR

950513114119

S.VIJAYA SHANMUGA SUNDAR

950513114118

X.VINISTEN

950513114120

P.ARUN KUMAR

950513114301

in partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
DR.SIVANTHI ADITANAR COLLEGE OF ENGINEERING
TIRUCHENDUR-628215

ANNA UNIVERSITY: CHENNAI 600 025

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APRIL 2016

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ANNA UNIVERSITY: CHENNAI 600 025

DR.SIVANTHI ADITANAR COLLEGE OF ENGINEERING
TIRUCHENDUR-628215
DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE

Certified that this project report

VERTICAL AIR-CONDITIONER WITH 360 AIR
FLOW

is

the

A.VIJAY SHANKAR,

bonafide

work

of

S.VIJAYA SHANMUGA

SUNDAR, X.VINISTEN, P.ARUN KUMAR.

Who

carried out the project work under my supervision.

SIGNATURE
DR.K.VENKEDESHWARAN.,M.E.,

SIGNATURE
MR.MELKIN JEBASINGH

Phd . ,MISTE.,

M.E.,(PhD.,)MISTE.,

INTERNAL EXAMINER

EXTERNAL EXAMINER

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ACKNOWLEDGEMENT
We thank our god his presence guidance with
us for the successful completion of this project.
First and foremost we express our sincere
gratitude to our beloved principle Dr. Jiji for
providing us an opportunity to carry out this
project
We sincerely acknowledge our thanks to DR. K.
VENKADESHWARAN, HOD/MECHANICAL, Dr.
Sivanthi Aditanar College of Engineering for
their kindest cooperation which made this project
a reality.
We also express our thanks to
MR.A.MANI RAMKUMAR and MR.J. GEORGE
MANIRAJ. FOR THEIR valuable guidance in
completing this project successfuly.
We sincerely thank MR.M.MELKIN
JEBASINGH, for his active involvement to make
this project successful.
We would like to acknowledge my
indebtedness to my colleagues for their timely
assistance and other departmental staffs whose
patience and support was instrumental in
accomplishing this task.
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We are thankful to our parents for their help of

finance in our project.

Preface
The project work may be defined as the
outcome of our theoritcal and practical
knowledge experiences and our responsibilities
from past three years. After entering tour
mechanical department we have studied third
fourth fifth and presently we are doing sixth
semester. The idea, which we got in these four
practical classes, we exactly apply them all to do
a project. However a single mman lone cannot do
a project when we form a group difference
student will give different idea,accordingly we
can have some good idea.By applying that we
can successfully complete our project.
We may have a lot more advantage when
doing a project, now a day if a student go for an
interview in any industry then the first question
for him from the interview committee is , what
type of project work have you done in the mini
project work? This will be definitely on that time
the student can explain the project work very
well and he can also win a opportunity.
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So the student should have got the knowledge

simply saying the project work is THE MUST for
every student . Hence we express our sincere
gratitude to our ANNA UNIVERSITY CHENNAI
for providing a paper on DESIGN AND
FABRICATION PROJECT on the sixth semester.

OBJECTIVES
The prolong convection of converging of vast syllabus in
the short span of time resulted in lack of knowledge of
technical knowledge and unaware of modern mechanics and
versatile application.
So in order to revise this situation and have clear
knowledge of modern mechanics and machine tools, project
work has been taken.
The project work resulted in requiring well defined in
requiring well defined knowledge about the machine tools
mechanisms and their veracity.
The project work includes the physical and mental
coordination of individual. The project work is taken mainly with
the objectives mentioned below:
The project work differs the regular practical
exercise, where emphasis is laid only in
developing the skill in different machine
process.
But it is a project apart from the skills,planning
of the project in specified time is involved.
Analysis and discussion on scheme the project
work enable the students to develop interest
and motivation and make them confident of the

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success in their endeavour hoping the above the

points in minds.
It evolves out the concept of group activity.
It further promotes co-operation , co-ordination
and ability of an individual.
Thus by analysis various projects and by
applying the above concepts , we carried out
our project of VERTICAL AIR-CONDITIONER
WITH 360 VERTICAL AIR FLOW.
We ourselves planned ,organised and executed to bring
out this project a successful one. Now we feel the sense of
achievement after our successful of our superior project
VERTICAL AIR-CONDITIONER WITH 360 VERTICAL AIR
FLOW.

ABSTRACT
Heat as always been a problem in every country such as
Malaysia. Doing work in a hot summer day can be tiring and are
prone to make silly and unwanted mistakes. A proper air
conditioner would be good item to have during these times.
When doing work or event, the place could become stuffy and
uncomfortable for technician or engineer. However, air
conditioners are mostly marketed as fix and hard to change
places portable air conditioners are dime a dozen but somehow
are very expensive to have. In this project, we aim to make a
portable air conditioner that is affordable and reliably cool small
confined for a limited amount of time and space..

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INTRODUCTION
VERTICAL 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.

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Construction and components

The whole construction of this system is simple and efficient.
The arrangement and position of components make this system
of to function.each and every component has its own property
and responsibility. To obtain a circular cooling the evaporator
coil is designed accordingly.the cpndensor unit is used for
effective cooling.Construction of proposed VERTICAL AIRCONDITIONER WITH 360 VERTICAL AIR FLOW consists
of four components. they are,
1.compressor
2.condensor
3.expansion valve
4.evaporator coil
5.blower

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Compressor
The AC compressor is the workhorse of the system and is driven by your cars engine
via a series of belts and pulleys. Its function is to transfer and compress gas from the
low-pressure (intake) side of the ac system to the high pressure (discharge) side of the
closed system. The ac compressor draws the refrigerant (while in gas state) from the ac
evaporator, where it has gathered heat from your vehicle interior. It then compresses the
gas refrigerant under high-pressure and send it off to the ac condenser. Once the hot
compressed gas enters the condenser, it begins to cool and expel heat as it travel
towards the bottom of the ac condenser where it has reverted back to a cool liquid state.
The cooled liquid gas then begins its journey back toward the ac evaporator. This gives
a general idea (oversimplified) how the process works. 35 SOLAR AIR CONDITIONER
B.S.P.P. 2014-15

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Condenser
The ac condenser and your cars radiator often look quite similar in appearance. The
compressor of the car generate compressed gas and sends it along to the top of the
condenser, where the gas begin to cool. The gas continues to cool and condense as it
makes it way through the serpentine-like coil arrangements, before exiting the bottom of
the condenser as a high-pressure liquid. The condenser is usually located in front of
your cars radiator. 36 SOLAR AIR CONDITIONER
B.S.P.P. 2014-15

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Expansion valve
Expansion valves regulate the amount of liquid refrigerant flowing from the condenser to
the evaporator based upon the evaporator pressure. A thermal expansion valve will
include a temperature sensor and meters the amount of refrigerant flowing into the
evaporator. 37 SOLAR AIR CONDITIONER
B.S.P.P. 2014-15

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Evaporator
The ac evaporator serves in multiple capacities, but its function is to absorb heat which
may have built up on a hot day inside your cars interior. The evaporator contains cold
Freon gas. The cold Freon gas passes through the evaporator and makes the
evaporator very cold. The ac blower fan is located behind the evaporator and blows air
across it and that cold air travels through the dash duct work and out the vents inside the
car. The water you see dripping from under the passenger side of the car is coming from
condensation at the evaporator core, and is a result of the AC system doing his job.

AC Blower motor
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The ac blower motor works in conjunction with the evaporator to remove heat and cool
your vehicle interior. He is usually located underneath the dash and connected to ducting
where it pulls-in the warm air from the interior and pushes it across the cool coils and
fins of the evaporator and send the cold air back to the cars interior.

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Working principle
In the Vertical Air conditioner, heat is transported from a colder location to a hotter area. As
heat would naturally flow in the opposite direction, work is required to achieve this. A
refrigerator is an example of such a system, as it transports the heat out of the interior and
into its environment. The refrigerant is used as the medium which absorbs and removes heat
from the space to be cooled and subsequently rejects that heat elsewhere.
Circulating refrigerant vapor enters the compressor and is compressed to a higher pressure,
resulting in a higher temperature as well. The hot, compressed refrigerant vapor is now at a
temperature and pressure at which it can be condensed and is routed through a condenser.
Here it is cooled by air flowing across the condenser coils and condensed into a liquid. Thus,
the circulating refrigerant removes heat from the system and the heat is carried away by the
air.
The condensed and pressurized liquid refrigerant is next routed through an expansion valve
where it undergoes an abrupt reduction in pressure. That pressure reduction results in flash
evaporation of a part of the liquid refrigerant, lowering its temperature. The cold refrigerant is
then routed through the evaporator. A fan blows the warm air (which is to be cooled) across
the evaporator, causing the liquid part of the cold refrigerant mixture to evaporate as well,
further lowering the temperature. The warm air is therefore cooled.
To complete the refrigeration cycle, the refrigerant vapor is routed back into the compressor

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FABRICATION
The operation we used in fabrication process are
1.fitting
2.welding
3.grinding
4.drilling
5.cutting
6.painting

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CUTTING

An abrasive saw, also known as a cut-off saw or

metal chop saw, is a power tool which is typically used to cut
hard materials, such as metals. The cutting action is performed
by an abrasive disc, similar to a thin grinding wheel. Technically
speaking this is not a saw, as it does not use regularly shaped
edges (teeth) for cutting. The abrasive saw generally has a
built-in vise or other clamping arrangement, and has the
cutting wheel and motor mounted on a pivoting arm attached
to a fixed base plate.

1. ABRASIVE SAW

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GRINDING

Grinding is an abrasive machining process that uses a

grinding wheel as the cutting tool.
A wide variety of machines are used for grinding:
Hand-cranked knife-sharpening stones (grindstones)

Handheld power tools such as angle grinders and die

grinders

Various kinds of expensive industrial machine tools called

grinding machines

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 Bench grinders often found in residential garages and

basements

2.GRINDING

WELDING

Welding is a fabrication or sculptural process that joins

materials, usually metals or thermoplastics, by causing fusion,
which is distinct from lower temperature metal-joining
techniques such as brazing and soldering, which do not melt
the base metal. In addition to melting the base metal, a filler
material is often added to the joint to form a pool of molten
material (the weld pool) that cools to form a joint that can be as
strong, or even stronger, than the base material.
Some of the best known welding methods include:
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 Shielded metal arc welding (SMAW) - also known as

"stick welding or electric welding", uses an electrode that
has flux around it to protect the weld puddle. The electrode
holder holds the electrode as it slowly melts away. Slag
protects the weld puddle from atmospheric contamination.
Gas tungsten arc welding (GTAW) - also known as TIG
(tungsten, inert gas), uses a non-consumable tungsten
electrode to produce the weld. The weld area is protected
from atmospheric contamination by an inert shielding gas
such as argon or helium.
Gas metal arc welding (GMAW) - commonly termed
MIG (metal, inert gas), uses a wire feeding gun that feeds
wire at an adjustable speed and flows an argon-based
shielding gas or a mix of argon and carbon dioxide (CO2) over
the weld puddle to protect it from atmospheric
contamination.
Flux-cored arc welding (FCAW) - almost identical to
MIG welding except it uses a special tubular wire filled with
flux; it can be used with or without shielding gas, depending
on the filler.
Submerged arc welding (SAW) - uses an automatically
fed consumable electrode and a blanket of granular fusible
flux. The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under the
flux blanket.
Electroslag welding (ESW) - a highly productive, single
pass welding process for thicker materials between 1 inch
(25 mm) and 12 inches (300 mm) in a vertical or close to
vertical position.

ARC WELDING
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Arc welding is a type of welding that uses a welding power

supply to create an electric arc between an electrode and the
base material to melt the metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and
consumable or non-consumableelectrodes. The welding region
is usually protected by some type of shielding gas, vapor, or
slag. Arc welding processes may be manual, semi-automatic, or
fully automated.

3.ARC WELDING

TYPES OF ARC WELDING ARE

1.COATED ELECTRODE ARC WELDING

2.INERT GAS WELDING
3.CORED WIRE ARC WELDING
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4.TIG WELDING

COATED ELECTRODE ARC WELDING Coated electrode arc

welding is a manual arc welding method where the heat
necessary for the welding is generated by the arc formed
between a coated wasting electrode and the workpiece.
Electrode's tip, welding bath, arc and the areas of the
workpiece near to the welding machine are protected against
the hazardous impact of the atmosphere by the gases formed
as a result of burning and separation of the coating material.
The slag formed by the melted coating material provides
additional protection for the melted welding metal in welding
bath. The additional metal (filler metal) is supplied by the core
wire of the wasting electrode and the metal dust in electrode
coating in some electrodes.

INERT GAS WELDING Inert gas welding is an arc welding

method where the heat necessary for the welding is generated
by the arc formed between a wasting electrode and the
workpiece. The solid wire electrode continuously supplied to
(applied on) the welding area is melted and consumed, forming
the welding metal. The electrode, welding bath, arc and the
areas of the workpiece near to the welding machine are
protected against the hazardous impact of the atmosphere by
the gas or mixed gas supplied from the welding torch. The gas
should be able to fully protect the welding area, otherwise a
very small air ingression causes errors on the welding metal

CORED WIRE ARC WELDING Arc welding with cored wire is an

arc welding method where the heat necessary for the welding is
generated by the arc formed between a wasting cored wire
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electrode and the workpiece. The protection of arc and welding

area is provided by the gases formed as a result of burning and
separation of the elementary substance in the cored wire or by
an externally supplied protective gas as is the case in inert gas
welding. The self-protected (open, arc based welding wires)
welding process is rather similar to the gas protection in coated
electrode welding method. The coating material on coated
electrodes causes production of flat bar shaped electrodes and
the length restrictions. In cored wires, , since the tubular wire is
within the electrode, and may be supplied to the continuous
welding area. This welding method may be applied for both
semi-automatic and full-automatic welding systems. The
disadvantage of welding with cored wire is that a slag layer,
which is similar to that in coated electrode arc welding but is a
little thinner, is formed on the weld bead. However, many types
of cored wire electrodes that don't require slag removal or don't
generate slag are being manufactured today.

TIG WELDING is an arc welding method where the heat

necessary for the welding is generated by the arc formed
between a non-wasting electrode (tungsten electrode) and the
workpiece. The electrode, welding bath, arc and the areas of
the workpiece near to the welding machine are protected
against the hazardous impact of the atmosphere by the gas or
mixed gas supplied from the welding torch. The gas should be
able to fully protect the welding area, otherwise a very small air
ingression causes errors on the welding metal.

SUBMERGED WELDING Submerged welding is an arc welding

method where the heat necessary for the welding is generated
by the arc(s) formed between a wasting electrode (or several
electrodes) and the workpiece. The arc area welding powder
layer as well as the welding metal and base metal close to the
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weld are protected by the melted welding powder (slag). In

submerged welding the electricity flows through the arc and the
welding bath consisting of melted metal and melted slag. The
arc heat electrode forms the welding bath that fills up the
welding bend by melting the melting powder and base metal.
The welding powder acting as a protective element also reacts
with the welding bath and deoxidizes the welding metal. The
welding powders used for welding the alloy steels may contain
alloy elements that compensate the chemical composition of
welding metal. Submerged welding is an automatic welding
method. In some submerged arc welding applications two or
more electrodes may be concurrently fed into the welding
bend. The electrodes may be fed into the welding bath as a
twin arc or may be successively fed with a distance sufficient to
ensure that the welding baths are individually hardened and
thereby a high welding speed and high metal accumulation
speed may be obtained.

DRILLING
Drilling is the operation of producing circular hole in the
work-piece by using a rotating cutter called DRILL.

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 The machine used for drilling is called drilling machine.

The drilling operation can also be accomplished in lathe,
in which the drill is held in tailstock and the work is held
by the chuck.
The most common drill used is the twist drill.

Drilling Machine

It is the simplest and accurate machine used in production

shop.
The work piece is held stationary ie. Clamped in position
and the drill rotates to make a hole.

Types

1) Based on construction:
Portable,
Sensitive,
Radial,
up-right,
Gang,
Multi-spindle

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2) Based on Feed:
Hand driven
Power driven

Components of drilling machine

Spindle
The spindle holds the drill or cutting tools and revolves in
a fixed position in a sleeve.

Sleeve
The sleeve or quill assembly does not revolve but may
slide in its bearing in a direction parallel to its axis. When the
sleeve carrying the spindle with a cutting tool is lowered, the
cutting tool is fed into the work: and when its moved upward,
the cutting tool is withdrawn from the work. Feed pressure
applied to the sleeve by hand or power causes the revolving
drill to cut its way into the work a fraction of an mm per
revolution.

Column
The column is cylindrical in shape and built rugged and
solid. The column supports the head and the sleeve or quill
assembly.

Head
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The head of the drilling machine is composed of the

sleeve, a spindle, an electric motor and feed mechanism. The
head is bolted to the column.

Worktable
The worktable is supported on an arm mounted to the
column. The worktable can be adjusted vertically to
accommodate different heights of work or it can be swung
completely out of the way. It may be tilted up to 90 degree in
either direction, to allow long pieces to be end or angle drilled.
Base
The base of the drilling machine supports the entire
machine and when bolted to the floor, provides for vibrationfree operation and best machining accuracy. The top of the
base is similar to the worktable and may be equipped with tslot for mounting work too larger for the table.

Hand Feed

The hand- feed drilling machines are the simplest and

most common type of drilling machines in use today. These are
light duty machine that are operated by the operator, using a
feed handled, so that the operator is able to feel the action of
the cutting tool as it cuts through the work piece. These drilling
machines can be bench or floor mounted.

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Power feed

The power feed drilling machine are usually larger and

heavier than the hand feed ones they are equipped with the
ability to feed the cutting tool in to the work automatically, at
preset depth of cut per revolution of the spindle these
machines are used in maintenance for medium duty work or
the work that uses large drills that require power feed larger
work pieces are usually clamped directly to the table or base
using t bolts and clamps by a small work places are held in a
vise. A depth stop mechanism is located on the head, near the
spindle, to aid in drilling to a precise depth.

Radial Drilling Machine

It the largest and most versatile used for drilling medium

to large and heavy work pieces.
Radial drilling machine belong to power feed type.
The column and radial drilling machine supports the radial
arm, drill head and motor. Fig.3 shows the line sketch of
radial drilling machine.

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4. Radial Drilling Machine

The radial arm slides up and down on the column with the
help of elevating screw provided on the side of the
column, which is driven by a motor.
The drill head is mounted on the radial arm and moves on
the guide ways provided the radial arm can also be
swiveled around the column.
The drill head is equipped with a separate motor to drive
the spindle, which carries the drill bit. A drill head may be
moved on the arm manually or by power.
Feed can be either manual or automatic with reversal
mechanism.

Tool holding devices

Fig.7 and Fig.8 shows the different work holding and drill
drift device.

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5.TOOL HOLDING DEVICES

Drilling operations

Operations that can be performed in a drilling machine are

Drilling:

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Drilling
Reaming
Boring
Counter boring
Countersinking
Tapping

It is an operation by which holes are produced in solid metal by

means of revolving tool called Drill. Fig. 9 shows the various
operations on drilling machine.

Reaming:
Reaming is accurate way of sizing and finishing the pre-existing
hole.
Multi tooth cutting tool. Accuracy of 0.005mm can be achieved

Boring:
Boring is a process of enlarging an existing hole by a single
point cutting tool. Boring operation is often preferred because
we can correct hole size, or alignment and can produce smooth
finish. Boring tool is held in the boring bar which has the shank.
Accuracy of 0.005mm can be achieved.

6. Various operations on drilling machine

Counter Bore :31 Vertical

This operation uses a pilot to guide the cutting action to

accommodate the heads of bolts. Fig. 10 illustrates the counter
boring, countersunk and spot facing processes.

Countersink:-

Special angled cone shaped enlargement at the end of the

hole to accommodate the screws. Cone angles of 60, 82, 90,
100, 110, 120

7. Counter boring, countersunk and spot facing

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Tapping:-

Tapping is the process by which internal threads are

formed. It is performed either by hand or by machine. Minor
diameter of the thread is drilled and then tapping is done. Fig.
11 show the tapping processes.

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8. Hand taps and tapping process using tap wrench

4..Fitting

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Fitting is the assembly of components to the frame and

removing metals to secure the necessary fits and may or may
not be carried out at the bench
Design
calculation
BLOWER MOTOR SPECIFICATION:
POWER
SPEED

: 3.73 Kw
: 900rpm

Moist air
Total cooling load at full load, Qc =60 kW
Latent Load at full load, QL =20 kW
Inlet air conditions = t = Dry and wet bulb temperatures are:
26 oC, and 19 oC
Air face velocity , V =2.8 m/s
Air heat transfer coefficient, hc =60 W/ (m2 oC)
Air mean specific heat, cpm =1.001 kJ/(kg. K)
R-134a
Evaporating temperature, Tev =7 oC
Heat transfer coefficient on refrigerant side, hi =2000 W/ (m 2 oC)
Number of tube-passes per water loop, Ntp = 6
Under the above design full load conditions, calculate:
a. The coil dimensions (tube length, finned width and coil depth).
b. The number of coil rows and the total number of tubes.
c. The exit air temperature.
Calculation Procedures
1. Knowing: [hain=54 kJ/kg, Wain=0.011 kgv/kga, QC=60 kW, CSHF=0.75, = %],
from the Psychometric-chart we obtain:
Air Exit Condition: [haout=33 kJ/kg, Tao=10.5 oC, Wao=0.86*10-3 kgv/kga]
2.

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A PROTOTYPE OF VERTICAL

AIR FLOW

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AIR-CONDITIONER WITH 360 VERTICAL

BILL OF MATERIALS
S.No.

MATERIAL

QUANTITY

1.

RECIPROCATING COMPRESSOR

1/8Th hp

2.

condensor

6X8

3.

Copper coil

6m

4.

Blower

5.

motor

6.

Expansion coil

0.53mm

7.

Angle column

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COST OF MATERIAL
S.No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

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MATERIAL
COMPRESSOR
COPPER COIL
MOTOR
BLOWER
EXPANSION COIL
CONDENSOR
FRAME
REFRIGERANT
METAL PLATE
BOLT AND NUT
THERMOCOAL
SHEET

QUANTITY
1
28
1
1
1
1
1
1 BOTTLE
1
8
2

COST
1000
700
600
200
110
425
500
1500
125
50
100

TOTAL

5310

11.CONCLUSION
It reduces the cost of air conditioning compare to normal air conditioner. It is
efficient for cooling in small area. Initial cost of its installation is high.We got
lot of knowledge regarding our field which is not available in the book. We
learnt how to work in team by dividing the load and work with team spirit.This
project is just a beginning and this can be researched in future according to
need.

VERTICAL AIRCONDITIONER WITH 360 VERTICAL AIR FLOW as a

superior and successful project.
Thus all the above features turned out our

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REFERENCES
TEXTBOOKS:

WEBSITES:

WWW.QUORA.COM
WWW.DUCKDUCKGO.COM
WWW.AIRCONDITIONING-SYSTEMS.COM
WWW.GOOGLE.CO.IN
WWW.GOOGLE.CO.IN/IMAGES

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