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 Problem Background 2. Concept Generation and Selection 3. Concept Development and Evaluation 4. Cost Projections 5. Summary

Background The Whalen Co. HVAC manufacturer –hospitals, apartment complexes, hotels Wants to boost sales of vertical water source heat pump –by offering additional options

Mission In the allotted time and as economically as possible FPED will: 1. Eliminate standing water in Whalen’s vertical heat pump 2. Decrease unit’s noise level 3. Improve circulation in the two-room units

Customers and Main Wants Internal to Whalen Executive Production Sales Engineering External Consumer NCDA Affordability, improved circulation. Ease of fabrication / installation. Affordability, improved circulation. Improved circulation, ease of fabrication. Affordability, quiet Design process

Constraints Size and geometry of unit and enclosure Regulatory commission specifications (ARI, UL) Unit’s current performance

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 Drain Pan sheet metal positive pitch Sound neoprene pads isolate insulate external baffles Two Room Draw return grilles sheet metal ducting

Metrics and Target Values Metric Cost of Materials Air Changes per Hour in adjacent room Number of Parts Fabrication Time Assembly Time Repair Time Decibel Level Footprint Change Target Value About $50 > /2 hours 2 hours 4 hours Less than Current Value 0

Prime Metrics Evaluated through SSD

Concept Generation Sound Designs diffusion ducting isolation insulation Drain Pan Designs sloped insert channel Two Room Air Draw Ducting above the fan below the coil adjacent to coil rotate coil above coil

Drain Pan Concept Selection Sloped Insert Disadvantages lengthy fabrication time difficult to install 4 additional parts (minimum)

Final Drain Pan Concept Channel Advantages 3 additional parts lower materials cost shorter fabrication time shorter assembly time

Sound Attenuation Concept Selection Diffusion Ducting Analysis flow rate =.189m 3 /s fan area =.0194m 2 the air velocity is v = Q/A = 9.75m/s non-turbulent flow  air flow is not generating noise non-turbulent flow  air flow is not generating noise

Final Sound Attenuation Concept Insulation double insulation of cabinet Isolation place neoprene between every metal to metal vibration point

Two Room Draw Concept Selection Rotate Coil changes footprint Above Fan difficult to maintain/repair Adjacent to Coil additional parts additional manufacturing costs minimal ducting area

Two Room Draw Concept Selection Duct underneath condenser coil Advantages fewer additional parts Disadvantages high assembly time changes foot print (required for significant flow)

Final Two Room Draw Concept Advantages no footprint change maximum ducting area easiest assembly

Overall Final Concept

Drain Pan Testing Procedure The Ideal Test Run unit for extended time and track condensation paths measure condensation amount

Drain Pan Testing Procedure Simulated Tests Pour water into the drain pan keeping the drain hole submerged at all times Measure the time it takes to drain a certain amount of water Mist water over coils with fan operating Results: average max flow rate of 1.51 GPM & vertical condensate flow

Two Room Draw Testing Procedure Procedure Place meter at center of duct Take three readings of air velocity, then average Calculate CFM and percentages of total air flow Trials New duct with deflector plate New duct with acoustical plate Original discharge with acoustical plate

Two Room Draw Test Results With deflector panel With acoustical panel

Sound Testing Procedure Procedure Obtain ambient baseline data Place decibel meter at selected locations Record three measurements at each point, then average Trials Insulate top of cabinet Insulate bottom of cabinet Isolate fan Isolate compressor

Sound Testing Results

Solution Satisfies Constraints and Metrics

Project Budget Allowable Budget = $5000  Expenditures  Visiting expenses$31.91  Model Materials$19.99  Prototype Materials  Sheet metal$25.00  Spray Adhesive$12.00  Tubing$1.00  Installation Materials$20.00 Total $109.90

Engineering Time Prototype Drawings 10 hours Fabrication 20 hours Installation 2 hours Testing Drain pan1 hour Sound6 hours Two room2 hours

Manufacturing Cost Projections Cost = Material + Manufacturing Time * Labor Manufacturing Time = Time to perform additional processes (shear, punch, etc.)

Drain Pan Manufacturing Projections Additional Processes fabricate inner channel solder channels cut hose pull T in riser Approximate Time 2 minutes 1 minutes 3 minutes

Sound Attenuation Projections Additional Processes cut neoprene cut insulation install insulation install neoprene Approximate Time 30 seconds 1 minutes 1 minute

Two Room Draw Projections Additional Processes fabricate duct attach duct notch hole in inner panel cut and attach neoprene to inner panel Approximate Time 4 minutes 2 minutes 30 seconds 1 minute

Summary In conclusion, FPED has created a design that: 1. Eliminates standing water in Whalen’s vertical heat pump 2. Decreases the unit’s noise level 3. Improves circulation in the two-room units by drawing from both rooms