COOLING SYSTEM INTEGRATED WITH MULTI-GYM

GUIDED BY Assoc.Prof ARUN MOHAN PRESENTED BY JITHIN K PAULOSE JOBY P MATHEW MANU K JOY PRINTO THOMAS YESUDHIN BABY

INTRODUCTION
Now a days Multi-gym has become an inevitable part in the life style of a majority of people. In the strive for maintaining the body and health, a lot of energy is wasted in the gymnasium. These energy can be utilized for some useful purposes and it would be a great advantage to the current state of conventional energy depletion.

GUIDING PRINCIPLE
First law of thermodynamics

ENERGY CAN NEITHER BE CREATED NOR DESTROYED, BUT CAN BE TRANSFORMED FROM ONE FORM TO ANOTHER

ABOUT
Our project deals with the utilization of the energy that is wasted in the gym. We use the simple but efficient method of direct cooling using a VORTEX TUBE. Compressed air required for working of vortex tube is obtained from compressor, which is driven by the gym cycle mechanism. Cold air from the vortex tube is used for various cooling purposes.

ENERGY TRANSFORMATION CYCLE

HUMAN EFFORT

COOLING EFFECT

MECHANICAL ENERGY

KINETIC ENERGY

PRESSURE ENERGY

MAIN COMPONENTS
GYM EXCER CYCLE

RECIPROCATING COMPRESSOR
STORAGE TANK VORTEX TUBE

GYM EXCER CYCLE

An immovable warm-up exercise machine. Rear wheel is attached to a Pulley. Energy transformation is made possible by :

SPROCKET

CHAIN

CHAIN DRIVE

RECIPROCATING COMPRESSOR
Mechanical energy is converted to pressure energy. Suction, Compression and discharge takes place in a cycle of intake and exhaust valve operation. The rated power is 0.25 HP. The rated speed is 1440 rpm.

DRIVE BELT

COMPRESSOR

BELT DRIVE

INSIDE THE COMPRESSOR

STORAGE TANK
Storage of compressed air from the compressor. Continuous flow of compressed air is ensured. In built pressure gauge, vent pipes, leak detector and pressure regulator are present. Max capacity of tank is 20 litre. Max pressure attainable is 115 psi.

CUT SECTION OF STORAGE TANK

VORTEX TUBE
Also known as the Ranque-Hilsch vortex tube. Cools and heats air at the SAME time with no moving parts, and no electricity. One of the non conventional type refrigerating system. Cooling effect is produced by the whirling of air in the vortex tube.

DESIGN
DESIGN OF CHAIN DRIVE:
Dimensional Specifications:

Input speed, N1 = No: of teeth at the input , T1 = No: of teeth at the output ,T2 =
Calculation Of Speed Ratio: = N2/N1 T1/T2 N2 = (T1/T2) x N1 = (46/14) x 60 = 197 rpm

60 rpm 46 14

Speed ratio ( i)

= =

N1/N2 60/197 =0.304

CHAIN DRIVE SPECIFICATIONS

DESIGN OF SHAFT
Torque to be transmitted =P*60/(2*N2*) =0.186*103*60/(2*197*) =9.016Nm =9.016*103Nmm

Equivalent twisting moment, (Te) =/16**D3 9.016*103 =/16*2.5*D3 D =15.3 ~15mm

DESIGN OF PULLEY: Dimensional specifications: Diameter of the Driver Pulley (D1)= 203mm Diameter of the Driven Pulley ( D2)= 178 mm Input Speed (N1) = 197rpm Rated Power (Rp) = 0.186 Kw Centre distance (C1) = 290mm Calculation of Speed Ratio : D1/D2 = N2/N1 N2 = (D1/D2) x N1 = (203/178) x 197 = 224.66 rpm ~ 225 rpm Speed ratio ( i) = N1/N2 = 197/203 = 0.97

BELT DRIVE SPECIFICATIONS

Centre distance (C1): C1 = 290 mm (Measured dimension) Lengths of belt drive (L): L = 2C1+[/2( D1 + D2)] +{(D2-D1)/4C1)} = ( 2 x 290 ) + [/2 (203 + 178)] + { (203-178) / ( 4 x 290) } = 584.676 mm ~ 585mm For an open belt drive; Sin = (D2-D1)/C1 =(178-203)/290 =-0.086 =4.930

Angle of lap on the smaller pulley , =1800-2 =1800-2*4.930 =170.140 =2.96rad Assume groove angle of pulley,2=340, =0.28 We know 2.3log(T1/T2) = cosec =0.28*2.96*cosec170 T1/T2 =2.83 Velocity of belt (V) =D1N1/60 =*203*197/60 =2.093m/s Area of belt (A) =13*8 =104mm2 Density of belt material () =1000kg/m3

Mass of belt per meter

= A* = 104*10-6*1000 = 0.104kg/m Centrifugal tension in belt (Tc) = mv2 = 0.104*2.0932 = 0.455N Maximum tension in belt (T) = *A = 2.5*104 = 260N Tension on tight side of belt (T1)= T-Tc = 260-0.455 = 259.545N

Tension on slack side of belt (T2) =T1/2.83 =259.545/2.83 =91.71N Power transmitted =(T1-T2)*v =(259.545-91.71)*2.093 =0.151kW The power to be transmitted is less than the obtained value so the design is safe. Number of belt required =0.186/0.151 =1

DESIGN OF VORTEX TUBE:

Dimensional specifications: Maximum velocity of the fluid (air) Inside diameter of pipe Pressure Discharge (Q) D = 15mm V = 2400m/min Q = Area * Velocity = 0.0076m^3/sec Thickness of pipe required (t)
v = D = P = 40m/s 15mm 0.5512N/mm^2

t = { (P * D)/(2 * z) } + C C = constant of pvc = 4.8 z = tensile stress for pvc = 7.4 N/mm^2 t = 5.35mm

.
Standard flange Nominal diameter of bolt d =.75t+10=14.0125mm No. of bolts n = .0275 D + 1.6=4 Thickness of the flange tf = 1.5 t +3=11.025mm Outside diameter of the flange (D 0) D 0 = D+2t+2B B = Width of flange = 2.3 d =32.228mm D0 = 90.156mm Pitch circle diameter (Dp) DP = D+2t+2d+12 = 65.725mm

Circumferential pitch (PC) Pc = (*DP)/n = 51.620mm In order to obtain the leak proof joint PC value lays between 10 d1^1/2 to 20 d1^1/2 d1 = diameter of the bolt hole =d+3=17.025mm Hence the value lies between 41.26 and 82.523. Hence the design is satisfactory.

DESIGN OF NOZZLE

d=D/2 D=diameter of block = 15mm d =diameter of nozzle = 7.5mm

ACTUAL VELOCITY OF FLUID C^2=2*Cp*(T1-T2) Cp =specific heat of air = 1.005 KJ/KgK T1 =Inlet temp of the air from the compressor = 38 T2 =Output temp of air at the cold tube = 22 C =5.67m/s

.
COP COP Uc T1 Tc T4 = Uc*(T1-Tc)/(T1-T4) = Fraction of cold air = 0.25 = Inlet temp of air to the vortex tube =38 = Outlet temp of the air at the cold tube= 22 = Adiabatic temp drop of air in 5.5 bar pressure = 18 COP = 0.2

FABRICATION
1. MARKING DIMENSIONS 2. CUTTING USING ABRASIVE CUTTER . 3. WELDING USING METAL ARC WELDING. 4. MACHINING OF PARTS IN LATHE, MILLING, DRILLING. 5. ASSEMBLING OF VARIOUS PARTS MADE.

6. 6. TRAIL RUN WAS DONE SUCCESSFULLY ANDANALYSIS WAS DONE

.
COMPARISSON OF THEORETICAL AND OBTAINED VALUE Theoretical Speed at the driver pulley of chain drive=60rpm Actual Speed at the driver pulley of chain drive=65rpm Theoretical Speed at the compressor pulley=225 rpm Actual Speed at the compressor=250rpm Measured temp at compressor outlet=38 degree celsius Measured temp at cold end of vortex tube=22 degree celcius

.
.

ORIFICEMETER FLANGES

NOZZLES

CAST IRON BLOCK

COMPLETED WORK
D

APPLICATIONS
Simple heating and cooling application . Refrigeration system. Heater Air cooler Liquefaction Condensation of water

SCOPE OF THE PROJECT

Integration of all system in a multi gym to obtain complete cooling of a gym. Wide amount of electricity used for cooling purposes can be eliminated. Heat energy available can be used for heating system in future. Hot bath spa can be developed. Water purification system.

CONCLUSION
Cooling system have been fabricated with atmost care. Further modification can be done by integrating all the system in a gym. Performance can be increased by the proper design of the unit.

REFERENCES
Project report on Design and fabrication of vortex tube by 2009 Batch. Refrigeration and Air Conditioning By R S Khurmi. Machine Design by Bhandri and R S Khurmi.

THANK YOU