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Ashish 123703 M.Tech. (AE)

The document discusses air conditioning systems and condensers. It provides details about: - How air conditioners use the phase change of refrigerants to absorb heat from interior air and transfer it outside. - The manufacturing process for residential condensers, including building the matrix core, brazing, testing for leaks, and final inspection. - Specifications for condenser components like the air center and methods to prevent defects like header bends during the brazing process.

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Ashish Parihar
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© Attribution Non-Commercial (BY-NC)
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Download as PPTX, PDF, TXT or read online on Scribd
47 views

Ashish 123703 M.Tech. (AE)

The document discusses air conditioning systems and condensers. It provides details about: - How air conditioners use the phase change of refrigerants to absorb heat from interior air and transfer it outside. - The manufacturing process for residential condensers, including building the matrix core, brazing, testing for leaks, and final inspection. - Specifications for condenser components like the air center and methods to prevent defects like header bends during the brazing process.

Uploaded by

Ashish Parihar
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Ashish 123703 M.Tech.

(AE)

Air Conditioning System:


When a liquid converts to a gas (in a process

called phase conversion), it absorbs heat. Air conditioners exploit this feature of phase conversion by forcing special chemical compounds to evaporate and condense over and over again in a closed system of coils. The compounds involved are refrigerants that have properties enabling them to change at relatively low temperatures.

The compounds involved are refrigerants that have

properties enabling them to change at relatively low temperatures. Air conditioners also contain fans that move warm interior air over these cold, , refrigerant-filled coils.

When hot air flows over the cold, low-

pressure evaporator coils, the refrigerant inside absorbs heat as it changes from a liquid to a gaseous state. A compressor puts the gas under high pressure, a process that creates unwanted heat. All the extra heat created by compressing the gas is then evacuated to the outdoors with the help of a second set of coils called condenser coils, and a second fan. As the gas cools, it changes back to a liquid, and the process starts all over again.

Condenser: Condenser is a highly efficient, compact heat


exchanger suitable for outdoor residential cooling units as well as chiller, transport truck, and bottle cooling applications. The coil is specially designed to condense discharge gas, as well as to provide liquid sub cooling.

Manufacturing Process of Residential Condenser:


Matrix core builder Fluxing(brazing) Cosmetic inspection Flame brazing FAG

Mass spec.
Shrink wrap Nitrogen charging and final insp.

Condenser specifications:
Air Centre: Air Centre is made up of Aluminum foil. It has

convolution count. Every convolution has louver angle. The use for Air centre is to increase the condense area beside the Tubes in Condenser which help easy and fast cooling of the engine through radiator.
and the process of producing Air centre is called Centre forming.

Centre Forming: Air centres are produced by Centre Machine

Air Centre and Its nomenclature: Air Centre:

Center Height:

8.08+/-.05 mm

CENTRE HEIGHT

Center Length:

714-720mm
CENTRE LENGTH

Louver angle: 25+/-2deg

LOUVER ANGLE

Convolution Count: 318+/-1

Other specifications:
No. of tubes:

50

Hdr to Hdr dimensions: 760+/-2 mm Reinforcement to Reinforcement: 534.5+/-1 mm Center to header gap:

5 mm

Matrix core builder:

Fluxing
Flux is an agent which prevents the Oxidation of

Aluminum from clad material and it also helps to move the clad towards joint. Fluxing helps the Brazing process. In 80% of application we use wet flux and in approx 15% application we use dry flux. In condenser we use wet flux called Nocolac flux. It takes 40-45 minutes. Fluxer Dryer Brazer Cooling Chamber Final cool

Post Brazing Operations:


Cosmetic inspection:

Flame Brazing:

FINAL ALLINMENT GAUGE (FAG)

Mass Spec testing:


In this test we applied the pressure of 225 psi of

Hellium and check the leakage through Mass Leak Test Machine

Shrink Wrap:

Nitogen charging and final inspection:


In this process at Proof test System nitrogen gas is

applied at the pressure of 500-520 psi and if condenser doesnt make any hissing sound then the condenser is Ok.

Defects in Residential Condenser:


1.Header Bend: Identified during cosmetic inspection

& FAG testing.

3. Bracket out: identified during cosmetic inspection

with the help of a gage.

4.Center crush:

Wire Winding Method


Braze Frame:a frame used for holding the core for proper

resting of core for brazing. Braze Bar insert: a component for supporting the header.

Steel wire: 2.25 meter wire pieces for winding the core at

four places. Fixture for winding: For holding the core perfectly to ease the winding.

Principle: Steel wire ensures expansion of core at

max. temp. of 600 deg Celsius without creating a thermal- bending stess in the header which was earlier causing HEADER BEND and Center crush problem.

Feasibility Study:
TRIAL 1 Tme(Min) Part1 15.45 Part2 12.42 Part3 13.25 Part4 9.01 Part5 8.2

Procedure: First put the core in the fixture such that braze frame is on

up side that will ease to remove the frame after winding. Cut the wire of 2.25 meter and insert the wire in the frame. Wind the core at 4 places with help of wire tighting gun. Remove the auxilliary frame and put the core on modified frame. Insert the Braze Bar Insert in braze bar. Ensure the tension of wire is up to requirement and core is ok to proceed for brazing in furnace.

TRIAL PARTS:

RESULTS:
Trial 1:
Part no. 1 2 3 4 5 6 7 8 9 10 Hdr bend No No Yes/Tight No No No No No Yes/Tight No Center drop Minor No Yes Minor No No No No Minor No Center crush No No No minor No No No No Minor No Bracket out No No No No No No No No No No Ok/rej Ok Ok Rej Ok Ok Ok Ok Ok Rej Ok

TRIAL 2:
Part no.
1 2 3 4 5 6 7 8 9 10

Hdr bend
No No Yes No No Yes No No Yes/Tight No

Center drop
Minor No No No No No No No Minor No

Center crush
No No No minor No No No No Minor No

Bracket out
No No No No No No No No No No

Ok/rej
Ok Ok Rej Ok Ok Ok Ok Ok Rej Ok

TRIAL 3:
Part no. 1 2 3 4 5 6 7 8 9 10 Hdr bend No No No No No No No No No No Center drop Minor No No No No No No No Minor No Center crush No No No No No No No No No No Bracket out No No No No No No No No No No Ok/rej Ok Ok Ok Ok Ok Ok Ok Ok Ok Ok

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