Four Points Engineering and Design

Project 99.04: Heat Pump Design for Whalen Co.

FPED Team Members: Ricardo Blackett, Andy Parke, Scott Quirico, Brian Zigmond

Presentation Agenda

1. Introduction and background 2. Method a. Concept Generation b. Concept Selection 3. Schedule and Budget

Background

• The Whalen Co. – HVAC manufacturer • hospitals, apartment complexes, hotels – Boost sales of vertical water source heat pump • • offer additional options offer improved health quality

Mission and Approach

1. Eliminate standing water 2. Decrease unit’s noise level 3. Improve circulation in the two-room units Develop Concept Present FPED’s Solution to Whalen Co.

Produce a unit that: • eliminates standing water • is quieter • has improved room circulation

Constraints

Size and geometry of unit and enclosure.

Regulatory commission specifications.

(ARI, UL)

Customers and Wants

Whalen Executive footprint Sales footprint Engineering circulation Production fabrication

System Benchmarking

• Trane: Well insulated unit gives quiet performance, removable drain pan for easy maintenance.

• ClimateMaster: Removable chassis for easy maintenance, sound-suppressing baffles on intakes.

Functional Benchmarking

• • Sound – – – – neoprene pads isolate insulate external baffles Two Room Draw – return grilles – sheet metal ducting • Drain Pan – sheet metal guide – – – positive pitch pump evaporation

Quality Metrics & Target Values

Metric Target Value % Footprint Change 0% Number of additional parts Time of fabrication 12 1.5 hours total

Concept Generation

3 Key Metrics Critical Functions Drain Pan minimal parts & time Two Room footprint & parts attach to coil internal ducting Sound Supression footprint & time internal to cabinet

Partial Concept Generation

• • Sound – – – diffusion ducting isolation insulation Drain Pan – – sloped insert channel • Two Room Air – – – – above the coil below the coil adjacent to coil rotate coil

Drain Pan Concept Selection

• Insert – high manufacturing cost – long time to fabricate

Final Drain Pan Concept

Sound Attenuation Concept Selection

• Diffusion Ducting – Not applicable • • Insulate and Isolate – every metal to metal vibration point – double insulate cabinet Testing – which points need isolation – optimum insulation thickness

Two Room Draw Concept Selection

• Rotate Coil – changes footprint • Above Coil – difficult to maintain/repair • Adjacent to Coil – – additional parts additional manufacturing costs – minimal air changes per hour

Final Two Room Draw Concept

• Duct underneath condenser coil

Overall Final Concept

Past Schedule

Future Schedule

By the ….

1 st week in December 2 nd week in December 3 rd week in December 1 st week in January 2 nd week in January 3 rd week in January 4 th week in January 1 st week in February We will …..

Have a scale model of fan coil and presented to NCDA Install unit for testing Obtain sound and drip data and analyzed.

Made prototypes for two room draw and drain pan Tested the protoypes with actual unit and obtain data Prepared a complete solution for Whalen Evaluate feedback from Whalen with advisor The possibilities of mass production discussed .

Estimated Engineering Time

• FPED – 4 hours building – 24 hours testing • The Whalen Co.

– 5 additional hours to implement final concept

Project Budget

•Total Budget = $5000  Expenditures to date  gas for trip to Whalen  photographs taken during visit  model materials(foam core)  Future Expenditures  decibel meter  battery 12 V $11.31

$ 9.29

$ 9.99

$45.00

$10.00