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ABSTRACT
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CHAPTER-1
ABSTRACT
35-40%, which means that only one-third of the energy in the fuel is converted
into useful work and about 60-65% is wasted to environment. In which about 28-
30% is lost by cooling water and lubrication losses, around 30-32% is lost in the
form of exhaust gases and remaining by radiation, etc. In this air conditioning
Compression System by using energy in the form of heat rather than mechanical
work. The heat required for running this type of air conditioning System can be
obtained from that which is wasted into the atmosphere from an IC engine.
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CHAPTER 2
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INTRODUCTION
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CHAPTER-2
INTRODUCTION
temperature of the enclosed space or substance and then maintaining that lower
for cars is to cool the space inside the car by utilizing waste heat and exhaust
Compression Refrigerant System (VCRS) which absorbs and removes heat from
the interior of the car which is the space to be cooled and further rejects the heat
engine shaft as the input power to drive the compressor of the refrigerant
system. Hence the engine has to produce extra work to run the compressor of the
air conditioning system thus utilizing extra amount of fuel. This loss of power of
the vehicle for air conditioning can be neglected by implementing this type of air
conditioning system.
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CHAPTER 3
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AIR CONDITIONING vs REFRIGERATION
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REFRIGERATION AND AIR CONDITIONING
In many ways air conditioning and refrigeration systems are very similar.
Both use specially designed chemicals, the physical effects of the compression and
expansion of gases, and the conversion of gas to liquid to reduce the temperature of
air. The varying uses of these systems, however, mean refrigeration and air
conditioning systems have a handful of key differences in the design and operation.
Supply
supply for the gases. Refrigeration systems have gas installed in a series of tubes.
In old refrigerators, this gas was chloro-flouro-carbon, or CFC, but this has
sole gas used as a coolant in refrigeration systems. Air conditioning systems use
built-in chemicals, but also air from the room or rooms being heated. Gases built
into air conditioning units cool air that circulates through the unit; the unit then
Circulation
Air conditioners have circulation systems designed to project cool air away
from the units while refrigeration units have circulation systems designed to retain
coolant in a confined space. Refrigeration systems circulate cool liquids and gases
through a series of tubes and vents. Cool air from within a refrigerator is sucked
into a compressor that recycles the gas through the tubes. Air conditioners, while
also employing tubes in the coolant system, have fans for the dispersal of air.
space, air conditioning systems disperse cool air throughout areas of unknown
volume.
Vaporization
gas in the cooling process, but the manner in which they achieve this is different
AIR CONDITIONING
conditions, typically with the aim of distributing the conditioned air to an occupied
space such as a building or a vehicle to improve thermal comfort and indoor air
quality. In common use, an air conditioner is a device that lowers the air
temperature.
The cooling is typically achieved through a refrigeration cycle, but
sometimes evaporation or free cooling is used. Air conditioning systems can also
In the most general sense, air conditioning can refer to any form of
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MANUFACTURING PROCESS
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CHAPTER-4
MANUFACTURING PROCESS
Manufacturing processes are the steps through which raw materials are
transformed into a final product. The manufacturing process begins with the
creation of the materials from which the design is made. These materials are then
tests and checks for quality assurance during or after the manufacturing, and
Usually, the portion that is fractured away is in small sized pieces, called chips.
drilling, grinding, turning and milling. Although the actual machines, tools and
processes for cutting look very different from each other, the basic mechanism for
causing the fracture can be understood by just a simple model called for orthogonal
cutting.
In all machining processes, the work piece is a shape that can entirely cover
the final part shape. The objective is to cut away the excess material and obtain the
final part. This cutting usually requires to be completed in several steps in each
step, the part is held in a fixture, and the exposed portion can be accessed by the
tool to machine in that portion. Common fixtures include vise, clamps, 3-jaw or 4-
jaw chucks, etc. Each position of holding the part is called a setup. One or more
cutting operation may be performed, using one or more cutting tools, in each setup.
To switch from one setup to the next, we must release the part from the previous
fixture, change the fixture on the machine, clamp the part in the new position on
the new fixture, set the coordinates of the machine tool with respect to the new
location of the part, and finally start the machining operations for this setup.
should try to do the entire cutting process in a minimum number of setups; the task
minimum number of) setups, and determination of the fixture used for each setup,
(ii) The orthogonal cutting model and tool life optimization and
Cold saws are saws that make use of a circular saw blade to cut through
various types of metal, including sheet metal. The name of the saw has to do with
the action that takes place during the cutting process, which manages to keep both
the metal and the blade from becoming too hot. A cold saw is powered with
electricity and is usually a stationary type of saw machine rather than a portable
type of saw.
The circular saw blades used with a cold saw are often constructed of high
speed steel. Steel blades of this type are resistant to wear even under daily usage.
The end result is that it is possible to complete a number of cutting projects before
there is a need to replace the blade. High speed steel blades are especially useful
when the saws are used for cutting through thicker sections of metal.
Along with the high speed steel blades, a cold saw may also be equipped
with a blade that is tipped with tungsten carbide. This type of blade construction
also helps to resist wear and tear. One major difference is that tungsten tipped
blades can be re-sharpened from time to time, extending the life of the blade. This
type of blade is a good fit for use with sheet metal and other metallic components
WELDING:
melting and fusing 1, the base metals being joined and 2, the filler metal applied.
Welding employs pinpointed, localized heat input. Most welding involves ferrous-
based metals such as steel and stainless steel. Weld joints are usually stronger than
works, tanks, furniture, boilers, general repair work and ship building.
OPERATION:
Several welding processes are based on heating with an electric arc, only a
few are considered here, starting with the oldest, simple arc welding, also known
normally coated with a mixture of chemicals or flux. An earth cable connects the
work piece to the welding machine to provide a return path for the current. The
weld is initiated by tapping ('striking') the tip of the electrode against the work
piece which initiates an electric arc. The high temperature generated (about
6000oC) almost instantly produces a molten pool and the end of the electrode
The operator needs to control the gap between the electrode tip and the work
covered with an extruded coating of flux. The heat of the arc melts the flux which
generates a gaseous shield to keep air away from the molten pool and also flux
ingredients react with unwanted impurities such as surface oxides, creating a slag
which floats to the surface of the weld pool. This forms a crust which protects the
weld while it is cooling. When the weld is cold the slag is chipped off.
The SMAW process cannot be used on steel thinner than about 3mm and
of electrode materials and coatings are available enabling the process to be applied
to most steels, heat resisting alloys and many types of cast iron.
DRILLNG:
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of
circular cross-section in solid materials. The drill bit is a rotary cutting tool, often
multipoint. The bit is pressed against the workpiece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge
against the workpiece, cutting off chips (swarf) from the hole as it is drilled.
OPERATION:
The geometry of the common twist drill tool (called drill bit) is complex; it
has straight cutting teeth at the bottom these teeth do most of the metal cutting,
and it has curved cutting teeth along its cylindrical surface. The grooves created by
the helical teeth are called flutes, and are useful in pushing the chips out from the
hole as it is being machined. Clearly, the velocity of the tip of the drill is zero, and
machine a small hole in the material, called a center-hole, before utilizing the drill.
Center-holes are made by special drills called center-drills; they also provide a
good way for the drill bit to get aligned with the location of the center of the hole.
There are hundreds of different types of drill shapes and sizes; here, we will only
Titanium Nitride coated steel); for cutting harder materials, drills with hard inserts,
In general, drills for cutting softer materials have smaller point angle, while
those for cutting hard and brittle materials have larger point angle;
need a special guiding support for the drill, which itself has to be very long; such
operations are called gun-drilling. This process is used for holes with diameter of
few mm or more, and L/D ratio up to 300. These are used for making barrels of
guns;
Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), since
the tool may break and get stuck in the work piece; - Usually, the size of the hole
made by a drill is slightly larger than the measured diameter of the drill this is
of the drill with the spindle axis, and some other factors;
For tight dimension control on hole diameter, we first drill a hole that is
slightly smaller than required size (e.g. 0.25 mm smaller), and then use a special
type of drill called a reamer. Reaming has very low material removal rate, low
INSPECTION:
inspection, (2) In-process inspection, and (3) Final inspection. In quality control
(which is guided by the principle that "Quality cannot be inspected into a product")
the role of inspection is to verify and validate the variance data; it does not involve
the semi-finished assembly moves from work station to work station where the
parts are added in sequence until the final assembly is produced. By mechanically
moving the parts to the assembly work and moving the semi-finished assembly
from work station to work station, a finished product can be assembled much faster
and with much less labor than by having workers carry parts to a stationary piece
for assembly.
NEED FOR AUTOMATION
Less Maintenance
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CHAPTER 5
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COMPONENTS AND DESCRIPTION
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CHAPTER-5
Compressor,
Condenser,
Expansion valve,
Evaporator,
Fan or blower,
IC engine.
COMPRESSOR
diesel or gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,
compressed air). By one of several methods, an air compressor forces more and
more air into a storage tank, increasing the pressure. When tank pressure reaches
its upper limit the air compressor shuts off. The compressed air, then, is held in the
tank until called into use. The energy contained in the compressed air can be used
for a variety of applications, utilizing the kinetic energy of the air as it is released
and the tank depressurizes. When tank pressure reaches its lower limit, the air
There are numerous methods of air compression, divided into either positive-
Positive displacement
compressors are:-
Piston-type air compressors use this principle by pumping air into an air
chamber through the use of the constant motion of pistons. They use one-
way valves to guide air into a cylinder chamber, where the air is compressed.
matching two helical screws that, when turned, guide air into a chamber,
Vane compressors use a slotted rotor with varied blade placement to guide
air into a chamber and compress the volume. A type of compressor that
this type, a rotating component imparts its kinetic energy to the air which is
eventually converted into pressure energy. These use centrifugal force generated
pressurizes it.
waste heat. Generally this is some form of air- or water-cooling, although some
(particularly rotary type) compressors may be cooled by oil (that is then in turn air-
compressors.
Most air compressors either are reciprocating piston type, rotary vane
There are two main types of air compressor's pumps: oil-lubed and oil-less. The
oil-less system has more technical development, but is more expensive, louder and
lasts for less time than oil-lubed pumps. The oil-less system also delivers air of
better quality.
(Horsepower) and CFM (cubic feet of air per minute). The gallon size of the tank
tells you how much compressed air "in reserve" is available. Gas/diesel powered
compressors are widely used in remote areas with problematic access to electricity.
They are noisy and require ventilation for exhaust gases. Electric powered
Compressor tank shapes are: "pancake", "twin tank", "horizontal", and "vertical".
CONDENSER
condense a substance from its gaseous to its liquid state, by cooling it. In so doing,
the latent heat is given up by the substance, and will transfer to the condenser
coolant. Condensers are typically heat exchangers which have various designs and
come in many sizes ranging from rather small (hand-held) to very large industrial-
For example, a refrigerator uses a condenser to get rid of heat extracted from
the interior of the unit to the outside air. Condensers are used in air conditioning,
industrial chemical processes such as distillation, steam power plants and other
heat-exchange systems. Use of cooling water or surrounding air as the coolant is
information, the goal is to provide some basic information on the different types of
Water-cooled
Air-cooled
Evaporative
Air cooled If the condenser is located on the outside of the unit, the air cooled
condenser can provide the easiest arrangement. These types of condensers eject
Most common uses for this condenser are domestic refrigerators, upright
freezers and in residential packaged air conditioning units. A great feature of the
air cooled condenser is they are very easy to clean. Since dirt can cause serious
more efficient type. Commonly used for swimming pools and condensers piped for
city water flow, these condensers require regular service and maintenance.
and the forming of algae, water cooled condensers require a constant supply of
Depending on the application you can choose from tube in tube, shell and
coil or shell and tube condensers. All are essentially made to produce the same
EXPANSION VALVE
conditioning a system that controls the amount of refrigerant flow into the
the working fluid. The valve needle remains open during steady state operation.
The size of the opening or the position of the needle is related to the pressure and
temperature of the evaporator. There are three main parts of the expansion valve
that regulate the position of the needle. A sensor bulb, at the end of the evaporator,
the diaphragm increases causing the needle to lower. Lowering the needle allows
more of the working fluid into the evaporator to absorb heat. The pressure at the
inlet of the evaporator affects the position of the needle and prevents the working
fluid from flowing back into the compressor. Since the pressure before the valve is
higher than the pressure after the valve, the working fluid naturally flows into the
evaporator. The pressure at the inlet of the evaporator acts on the diaphragm. There
is also a spring providing a constant pressure closing the valve needle. The spring
on temperature needs. The pressure created by the spring acts on the opening of the
valve. When the pressure of the sensor bulb acting on the diaphragm is greater than
the combined pressure of the evaporator and spring, the valve opens to increase the
flow rate of the working fluid. An increase of flow rate lowers the temperature of
valves is how the evaporator pressure affects the position of the needle. In
internally equalized valves, the evaporator pressure against the diaphragm is the
pressure at the inlet of the evaporator, whereas in externally equalized valves, the
evaporator pressure against the diaphragm is the pressure at the outlet of the
having low pressure drop. Externally equalized valves must be used on multi-
EVAPORATOR
An evaporator is a device used to turn the liquid form of a chemical into its
cooling chemical, such as R-22 (Freon) or R-410A, to evaporate from liquid to gas
while absorbing heat in the process. It can also be used to remove water or other
foods and chemicals as well as salvage solvents. In the concentration process, the
goal of evaporation is to vaporize most of the water from a solution which contains
the desired product. In the case of desalination of sea water or in Zero Liquid
beverage industry. Foods or beverages that need to last for a considerable amount
in Kraft pulping. Cutting down waste-handling cost is another major reason for
these methods are costly. By removing moisture through vaporization, industry can
The solution containing the desired product is fed into the evaporator and
passes across a heat source. The applied heat converts the water in the solution into
vapor. The vapor is removed from the rest of the solution and is condensed while
section contains the heating medium, which can vary. Steam is fed into this
section. The most common medium consists of parallel tubes but others have plates
separating section removes the vapor being produced from the solution. The
condenser condenses the separated vapor, then the vacuum or pump provides
mediums in the evaporators. In foods, proteins and polysaccharides can create such
deposits that reduce the efficiency of heat transfer. Foaming can also create a
problem since dealing with the excess foam can be costly in time and efficiency.
Antifoam agents are to be used, but only a few can be used when food is being
processed.
Corrosion can also occur when acidic solutions such as citrus juices are
concentrated. The surface damage caused can shorten the long-life of evaporators.
Quality and flavor of food can also suffer during evaporation. Overall, when
choosing an evaporator, the qualities of the product solution need to be taken into
careful consideration.
FAN OR BLOWER
number of blades, connected to a hub and shaft, and driven by a motor or turbine.
The flow rates of these fans range from approximately 200 to 2,000,000 cubic feet
(5.7 to 57000 cubic meters) per minute. A blower is another name for a fan that
operates where the resistance to the flow is primarily on the downstream side of
the fan.
Most blowers may be categorized into one of two general types: centrifugal
Centrifugal
disk, with blades mounted at right angles to the disk, to impart movement to the air
or gas and increase its pressure. The assembly of the hub, disk and blades is known
as the fan wheel, and often includes other components with aerodynamic or
structural functions. The centrifugal fan wheel is typically contained within scroll-
shaped fan housing, resembling the shell of the nautilus sea creature with a central
hole. The air or gas inside the spinning fan is thrown off the outside of the wheel,
to an outlet at the housing's largest diameter. This simultaneously draws more air
or gas into the wheel through the central hole. Inlet and outlet ducting are often
attached to the fan's housing, to supply and/or exhaust the air or gas to the
industry's requirements.
There are many varieties of centrifugal fans, which may have fan wheels that
range from less than a foot (0.3 meters) to over 16 feet (5 m) in diameter.
Axial
The axial design uses axial forces to achieve the movement of the air or gas,
spinning a central hub with blades extending radially from its outer diameter. The
fluid is moved parallel to the fan wheel's shaft, or axis of rotation. The axial fan
In general, axial fans are used where the principal requirement is for a large
volume of flow, and the centrifugal design where both flow and higher pressures
are required.
IC ENGINE
CONSTRUCTION
In this project we use SPARK IGNITION engine of the type two stroke
single cylinder of Cubic capacity 75 cc. Engine has a piston that moves up and
down in cylinder. A cylinder is a long round air pocket somewhat like a tin can
with a bottom cut out. Cylinder has a piston which is slightly smaller in size than
the cylinder the piston is a metal plug that slides up and down in the cylinder Bore
diameter and stroke length of the engine are 50mm and 49mm respectively.
WORKING
There are only two strokes involved namely the compression stroke and the
power stroke; they are usually called as upward stroke and downward stroke
respectively.
Upward Stroke
During this stroke, the piston moves from bottom dead center to top dead
cylinder.
At the time the inlet port is uncovered and the exhaust, transfer ports are
Downward Stroke
The charge is ignited the hot gases compress the piston moves downwards,
during this stroke the inlet port is covered by the piston and the new charge is
first exhaust port and then transfer port and hence the exhaust starts through the
exhaust port. As soon as the transfer port open the charge through it is forced in to
CHAPTER 6
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WORKING PRINCIPLE
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CHAPTER-6
WORKING PRINCIPLE
The unit consists of four main parts - the boiler, condenser, evaporator and
the absorber. The unit can be run on waste exhaust gas heat. When the unit
operates on the exhaust gas, the heat is supplied by the exhaust gas which is fitted
underneath the central tube and when the unit operates on electricity the heat is
sufficient pressure to condense ammonia at the room temperature for which the
unit is designed. When heat is supplied to the boiler system, bubbles of ammonia
gas are produced which rise and carry with them quantities of weak ammonia
This weak solution passes into the tube, whilst the ammonia vapour passes
into the vapour pipe and on to the water separator. Here the water vapor is
condensed and runs back into the boiler system leaving the dry ammonia vapour to
pass to the condenser. Air circulating over the fins of the condenser removes the
heat from the ammonia vapour to cause it to condense into liquid ammonia which
flows into the evaporator. The evaporator is supplied with hydrogen. The hydrogen
passes across the surface of the ammonia and lowers the ammonia vapour pressure
continuous trickle of weak ammonia solution fed by gravity from the tube. This
weak solution, flowing down through the absorber comes into contact with the
mixed ammonia and hydrogen gases which readily absorbs the ammonia from the
mixture, leaving the hydrogen free to rise through the absorber coil and to return to
the evaporator.
The hydrogen thus circulates continuously between the absorber and the
evaporator. The strong ammonia solution produced in the absorber which flows
down to the absorber vessel and then to the boiler system, thus completing the full
cycle of operation. The liquid circulation of the unit is purely gravitational. Heat is
This heat must be dissipated into the surrounding air. Heat must also be
dissipated from the condenser in order to cool the ammonia vapour sufficiently for
it to liquefy. Free air circulation is therefore necessary over the absorber and the
condenser. The whole unit operates by the heat applied to the boiler system and it
is of paramount importance that this heat is kept within the necessary limits and is
properly applied.
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CHAPTER 7
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2D DRAWING
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CHAPTER-7
2D DRAWING
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CHAPTER 8
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ADVANTAGES AND DISADVANTAGES
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CHAPTER-8
ADVANTAGES
The running cost of this system is less than air conditioning system.
Among the refrigerant circulated is less per ton of refrigeration than air
the latent heat. As a result of this, the size of evaporator is smaller for the
adjusting the expansion valve of the same unit, the required temperature
DISADVANTAGES
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APPLICATIONS
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CHAPTER-9
APPLICATIONS
The air conditioning effect from the waste heat from the cars has a wide
Commercial vehicles.
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CONCLUSION
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CHAPTER-10
CONCLUSION
planning, purchasing, assembling and machining while doing this project work.
We are proud that we have completed the work with the limited time
We have done to our ability and skill making maximum use of available
which helps to know how to achieve low cost air conditioning using the exhaust
gas. By using more techniques, they can be modified and developed according to
the applications.