PROJECT

ON
MANUFACTURING
&
SERVICE

SUBMITTED TO:

JASDEEP SINGH CHADDA SUBMITTED BY:

SMIT DESAI

AMOL

MANSHA

VIDHU

GAURAV

R. Vishvanath
 MANUFACTURING PROCESS OF AIR CONDITIONER

RAW MATERIALS

1. Air conditioners are made of different types of metal.

2. Plastic and other nontraditional materials are used to reduce weight and cost.

3. Copper or aluminum tubing, critical ingredients in many air conditioner components, provide
superior thermal properties and a positive influence on system efficiency.

4. Various components in an air conditioner will differ with the application, but usually they are
comprised of stainless steel and other corrosion-resistant metals.

5. Self-contained units that house the refrigeration system will usually be encased in sheet metal
that is protected from environmental conditions by a paint or powder coating.

6. The working fluid, the fluid that circulates through the air-conditioning system, is typically a
liquid with strong thermodynamic characteristics like freon, hydrocarbons, ammonia, or water.

DESIGN
All air conditioners have four basic components:

1. A pump,

2. An evaporator

3. A condenser

4. An expansion valve. All have a working fluid and an opposing fluid medium as well.
Two air conditioners may look entirely dissimilar in both size, shape, and configuration, yet both
function in basically the same way. This is due to the wide variety of applications and energy sources
available. Most air conditioners derive their power from an electrically-driven motor and pump
combination to circulate the refrigerant fluid. Some natural gas-driven chillers couple the pump with a
gas engine in order to give off significantly more torque.

As the working fluid or refrigerant circulates through the air-conditioning system at high pressure via
the pump, it will enter an evaporator where it changes into a gas state, taking heat from the opposing
fluid medium and operating just like a heat exchanger. The working fluid then moves to the condenser,
where it gives off heat to the atmosphere by condensing back into a liquid. After passing through an
expansion valve, the working fluid returns to a low pressure state. When the cooling medium (either a
fluid or air) passes near the evaporator, heat is drawn to the evaporator. This process effectively cools
the opposing medium, providing localized cooling where needed in the building. Early air conditioners
used freon as the working fluid, but because of the hazardous effects freon has on the environment, it
has been phased out. Recent designs have met strict challenges to improve the efficiency of a unit,
while using an inferior substitute for freon.

THE MANUFACTURING PROCESS

CREATING ENCASEMENT PARTS FROM GALVANIZED SHEET METAL AND

STRUCTURAL STEEL

1. Air conditioners start out as raw material, in the form of structural steel shapes and sheet
steel.

2. As the sheet metal is processed into fabrication cells or work cells, it is cut, formed,
punched, drilled, sheared, and/or bent into a useful shape or form.

3. The encasement or wrappers, the metal that envelopes most outdoor residential units, is
made of galvanized sheet metal that uses a zinc coating to provide protection against
corrosion.

4. Galvanized sheet metal is also used to form the bottom pan, face plates, and various support
brackets throughout an air conditioner.
 5. This sheet metal is sheared on a shear press in a fabrication cell soon after arriving from
storage or inventory.

6. Structural steel shapes are cut and mitered on a band saw to form useful brackets and
supports.

PUNCHING PRESSING THE SHEET METAL FORMS

1. From the shear press, the sheet metal is loaded on a CNC (Computer Numerical Control)
punch press.
2. The punch press has the option of receiving its computer program from a drafting
CAD/CAM (Computer Aided Drafting/Computer Aided Manufacturing) program or from an
independently written CNC program.
3. The CAD/CAM program will transform a drafted or modeled part on the computer into a
file that can be read by the punch press, telling it where to punch holes in the sheet metal.
4. Dies and other punching instruments are stored in the machine and mechanically brought to
the punching arm, where it can be used to drive through the sheet.
5. The NC (Numerically Controlled) press brakes bend the sheet into its final form, using a
computer file to program itself.
6. Different bending dies are used for different shapes and configurations and may be changed
for each component.
7. Some brackets, fins, and sheet components are outsourced to other facilities or companies
to produce large quantities. They are brought to the assembly plant only when needed for
assembly.
8. Many of the brackets are produced on a hydraulic or mechanical press, where brackets of
different shapes and configurations can be produced from a coiled sheet and unrolled
continuously into the machine
9. . High volumes of parts can be produced because the press can often produce a complex
shape with one hit.

CLEANING THE PARTS

1. All parts must be completely clean and free of dirt, oil, grease, and lubricants before they are
powder coated.
 2. Various cleaning methods are used to accomplish this necessary task.

3. Large solution tanks filled with a cleaning solvent agitate and knock off the oil when parts
are submersed.

4. Spray wash systems use pressurized cleaning solutions to knock off dirt and grease.

5. Vapor degrease, suspending the parts above a harsh cleansing vapor, uses an acid solution
and will leave the parts free of petroleum products.

6. For additional corrosion protection, many parts will be primed in a phosphate primer bath
before entering a drying oven to prepare them for the application of the powder coating.

POWDER COATING

1. Before brackets, pans, and wrappers are assembled together, they are fed through a powder
coating operation.

2. The powder coating system sprays a paint-like dry powder onto the parts as they are fed
through a booth on an overhead conveyor.

3. This can be done by robotic sprayers that are programmed where to spray as each part feeds
through the booth on the conveyor.

4. The parts are statically charged to attract the powder to adhere to deep crevices and bends
within each part.

5. The powder-coated parts are then fed through an oven, usually with the same conveyor
system, where the powder is permanently baked onto the metal. The process takes less than
10 minutes.

BENDING THE TUBING FOR THE CONDENSER AND EVAPORATOR

1. The condenser and evaporator both act as a heat exchanger in air conditioning systems and
are made of copper or aluminum tubing bent around in coil form to maximize the distance
through which the working fluid travels.
2. The opposing fluid, or cooling fluid, passes around the tubes as the working fluid draws
away its heat in the evaporator.
3. This is accomplished by taking many small diameter copper tubes bent in the same shape
and anchoring them with guide rods and aluminum plates.
 4. The working fluid or refrigerant flows through the copper tubes and the opposing fluid
flows around them in between the aluminum plates.
5. The tubes will often end up with hairpin bends performed by NC benders, using the same
principle as the NC press brake.
6. Each bend is identical to the next ,the benders use previously straightened tubing to bend
around a fixed die with a mandrel fed through the inner diameter to keep it from collapsing
during the bend. The mandrel is raked back through the inside of the tube when the bend has
been accomplished.
7. Tubing supplied to the manufacturer in a coil form goes through an uncoiler and straightener
before being fed through the bender.

8. Some tubing will be cut into desired lengths on an abrasive saw that will cut several small
tubes in one stroke.

9. The aluminum plates are punched out on a punch press and formed on a mechanical press to
place divots or waves in the plate.

10. These waves maximize the thermodynamic heat transfer between the working fluid and the
opposing medium.

11. When the copper tubes are finished in the bending cell, they are transported by automatic
guided vehicle (AGV) to the assembly cell, where they are stacked on the guide rods and
fed through the plates or fins.

JOINING THE COPPER TUBING WITH THE ALUMINIUM PLATES

1. A major part of the assembly is the joining of the copper tubing with the aluminum plates.
2. This assembly becomes the evaporator and is accomplished by taking the stacked copper
tubing in their hairpin configuration and mechanically fusing them to the aluminum plates.
3. The fusing occurs by taking a bullet, or mandrel, and feeding it through the copper tubing to
expand it and push it against the inner part of the hole of the plate.
4. This provides a thrifty, yet useful bond between the tubing and plate, allowing for heat
transfer.
5. The condenser is manufactured in a similar manner, except that the opposing medium is
usually air, which cools off the copper or aluminum condenser coils without the plates.
 6. They are held by brackets which support the coiled tubing, and are connected to the
evaporator with fittings or couplings.
7. The condenser is usually just one tube that may be bent around in a number of hairpin
bends.
8. The expansion valve, a complete component, is purchased from a vendor and installed in the
piping after the condenser. It allows the pressure of the working fluid to decrease and re-
enter the pump.

INSTALLING THE PUMP

1. The pump is usually purchased from outside.

2. Designed to increase system pressure and circulate the working fluid, the pump is connected
with fittings to the system and anchored in place by support brackets and a base.

3. It is bolted together with the other structural members of the air conditioner and covered by
the wrapper or sheet metal encasement. The encasement is either riveted or bolted together
to provide adequate protection for the inner components.

SERVICE
APOLLO HOSPITAL

Corporate Services offered at Apollo Hospitals, Chennai

As the architect of healthcare in India, Apollo Hospitals has virtually redefined corporate health
services. From wellness to preventive care to treatment of illnesses to rehabilitation, Apollo Hospitals
has invested in every link of the healthcare chain.
Today with the experience of over one million health checks, Apollo Hospitals has emerged as a key
player in the corporate health care sector. Over 500 leading corporates, across all segments of industry,
have tied up with Apollo Hospitals. For their employees this means ready-access to some of the most
sophisticated medical facilities at over 43 locations in India. The corporate services initiative of Apollo
Hospitals, Chennai is to not merely providing world standard health care, but more importantly
bringing it within the reach of every individual.
Corporate Services

• Customized Preventive Health Checks

 • Outpatient Facilities

• Consultation across 57 Specialties

• Inpatient Facility

• Priority Admission

• Radiation Packages

• Choice of rooms

• Exclusive diet for patients

• Multi-cuisine Service
Emergency & Trauma

• Fully-equipped ambulance capable of handling all emergencies

• Toll free Emergency number 1066

• Telemedicine

• On site Telemedicine facility in areas where medical consultation is not available

• Occupational Health Centre

• On-site Doctor

• Medical Manpower Assistance

• Ambulance Service

• Management of Medical Centre-Designing, Equipment & Maintenance, Providing & Training

Manpower, Medicine Supplies, Day-to-day Operations

Corporate Plus

• Screening Camps

• Awareness Lectures

• Open Session with doctors

• Health and Wellness Workshops

Other Services

• Corporate/Insurance Help Desk

• Cashless facility
 • Complimentary medical and lifestyle journals

• Privilege Card

• Guest accommodation

• Bank and ATM facility

Inpatient Services

Admission (Ext: 2058, 2060)

In the event of your requiring admission, your doctor would fill out an Admission Request Form. The
reception counter will send your file with the admission request to the admission counter at gate no:6.
If your admission is planned, please contact the admission counter before you reach the hospital at
above mentioned admissions counter's extensions.

Room Categories
Indraprastha Apollo Hospitals provide a range of options to meet the needs and budgets of all patients
from budget-minded four bedded rooms to suites. All rooms have been designed with your comfort and
safety in mind. Effort is made to provide the type of room that you desire. However, in the even of non-
availability of the room of your choice, you will be allotted the best alternative room available.

All the rooms include the following exclusive features:

Categories Common Room Amenities
» A/C consists of 4, 5 or 6 beds separated by curtains
partitions.
A/C Multibed
» Common TV with cable connection
Unit
» Telephone for incoming calls.
» For attendant a dari and a pillow
» Each room accommodation 2 patients
» Common TV with cable connection
Semi-Private
» Separate telephones are provided.
» For attendant bedding will be provided.
» Single bed A/c units.
» TV and telephone facility
Single Room
» Wardrobe with a large bathroom
» Sofa cum bed is provided for the attendant
» Room larger in size
» Provided with refrigerator
Deluxe
» Spacious bathroom and includes all other facilities
of a single room.
Suite » Large bath attached to patient's room
» Pantry
» Lounge
» Separate bathroom for the attendants.
» Special patient bed with remote control facility for
 various reclining positions for patient comfort is
provided

Intensive Care Units (Ext: 2155, 2189, 2191)

30 percent of the total beds in Apollo are dedicated to intensive care. The ICUs ae equipped with most
modern patient monitoring systems. Trained intensivists are present in the ICUs round the clock. One
attendant is allowed to be in the ICU lobby for each patient.

Visiting Hours (Ext: 2155, 2189, 2191)

CTVS ICU 04:30pm-05:30pm
Other ICUs 05:30pm-06:30pm
A prayer room and a 24-hour fast food center are located in the ICU lobby for your convenience.

Day care rooms (Ext: 2137, 2138)

Ambulatory care at Apollo is one of its kinds in India. The day care rooms are provided for ambulatory
procedure and day surgeries, which do not require admission for more than 12 hours. e.g. D&C,
Chemotherapy, Cataract Surgery etc. tariff is charged on hourly basis to contain costs for the patient.

TPA / Insurance (Ext: 1843, 2042)

If you are covered with listed Third Party Administrators for medical services, Apollo Hospitals, Delhi,
will help you get your claims processed by your TPA. For assistance, please contact TPA Helpdesk at
the extension numbers.

Pharmacy (Ext: 1865,1866)

All your requirements of medicine will be catered for by the inpatient pharmacy, which is open round
the clock. In case of emergency, the medicines will be used from nursing stock and later replaced from
the pharmacy.

Corporate Helpdesk (Ext: 1846)

If your company has tied up with Apollo Hospitals for medical services, you would be entitled to
certain privileges as a corporate client. For assistance, please contact Corporate Helpdesk at their
extension.

Biblography

This report is used by the students of IILM Institute for Higher Education for internal marks purpose.