Design and fabrication of smart portable air conditioner

DESIGN AND FABRICATION OF SMART
PORTABLE AIR CONDITIONER
MOHAMAD AZRIL AFIF BIN GHAZALI
UNIVERSITI KUALA LUMPUR MALAYSIAN
INSTITUTES OF AVIATION ENGINEERING
TECHNOLOGY
JULY2013

4
ACKNOWLEDGEMENT
The final year project entitled ― Design and Fabrication of Smart Portable Air
conditioner‖ was successfully finished with the of everyone who participated and
supported me from the beginning to the end of this project. In this opportunity, I
would like to thank on my family and my friends because of their understanding to all
my effort on this project.
A special thanks I given to Mr Abdul Aziz Bin Ahmad and Mr Khir Bin Harun
as my supervisor and co supervisor who were guided and giving full attention to
finish this project. All their suggestions and ideas were very brilliant which very
helpful to apply in this project. The constant support from them leads this project to be
succesull.
Beside that, to a very special person Mr Ahmad Zaini Bin Idris from Giat Mara
Teluk Intan that I would to thanks because of giving permission to use his workshop
and helping on finding the components and material for this project.
Finally, I would like to express my full appreciation to all my comrades from ―
Bachelor Mechanical Semester 7‖ on giving support and sharing ideas. Without them,
this project may not be established.

5
LIST OF TABLES
1. Table 1 : Result Of Test
2. Table 2 :Distance of Cold Air Can Travel

6
LIST OF FIGURES
1. Figure 1 : Minimal Air Conditioning
2. Figure 2 : Evaporator
3. Figure 3 : Condensor
4. Figure 4 : Expansion Valve
5. Figure 5 : Compressor
6. Figure 6 : Decoration Of Tree In Outdoor
7. Figure 7 : Decoration Of Tree On Stage
8. Figure 8 : Final Product Of Smart Portable Air Conditioner
9. Figure 9 : Flexible Hose
10. Figure 10 : Blower of Broken Window Air Conditioner
11. Figure 11 : Originally of Broken Compressor
12. Figure 12 : Composite Body Of Portable Air Conditioner
13. Figure 13 : Design of The Smart Portable Air Conditioner

7
ABSTRACT
Heat as always been a problem in every country such as Malaysia.
Doing work in a hot summer day can be tiring and are prone to make silly
and unwanted mistakes. A proper air conditioner would be good item to
have during these times. When doing work or event, the place could
become stuffy and uncomfortable for technician or engineer. However, air
conditioners are mostly marketed as fix and hard to change places
portable air conditioners are dime a dozen but somehow are very
expensive to have. In this project, we aim to make a portable air
conditioner that is affordable and reliably cool small confined for a
limited amount of time and space..

8
CONTENTS
LIST OF TABLES
LIST OF FIGURES
ABSTRACT
CHAPTER 1: INTRODUCTION ............................................................................................ 10
1.1. Portable Air Conditioning system ............................................................................. 10
1.2. Statement Of Problem ............................................................................................... 11
1.3. Objective.................................................................................................................... 12
1.4. Scope And Limitation................................................................................................ 12
CHAPTER 2: LITERATURE REVIEW ................................................................................. 13
5.1 A Short History Of Refrigerant-Cycle Air Conditioners........................................... 13
5.2 General Air Conditioning System ............................................................................. 14
5.3 Air-Conditioning Processes....................................................................................... 17
5.4 Type Of Air Conditioning Systems........................................................................... 18
4.2.1 Central Air Conditioning Systems. .................................................................... 18
4.2.2 Unitary Air Conditioning Systems..................................................................... 19
4.2.3 Room Air Conditioning Units............................................................................ 19
4.2.4 Built-up Systems. ............................................................................................... 20
4.2.5 Split System Air Conditioners............................................................................ 20
5.5 Air Conditioning System Components...................................................................... 21
5.6 Outdoor Design Conditions....................................................................................... 23
5.7 Motion Sensor............................................................................................................ 25
5.8 Design Of Tree As Decoration .................................................................................. 27
5.9 PORTABLE AIR CONDITIONER .......................................................................... 29
4.2.1 EARLY DATA ROOM ..................................................................................... 29
4.2.2 RENTAL MARKET .......................................................................................... 30

9
4.2.3 CONTRACTOR SOLUTIONS.......................................................................... 31
CHAPTER 3 METHODOLOGY............................................................................................. 32
5.1 THEORETICAL ANALYSIS................................................................................... 33
4.2.1 Group Discussion ............................................................................................... 33
4.2.2 Final year project topic....................................................................................... 33
4.2.3 Time frame of the project................................................................................... 33
4.2.4 Risk and analysis of this project successfully. ................................................... 34
4.2.5 Internet ............................................................................................................... 34
4.2.6 Design Analysis.................................................................................................. 34
4.2.7 Visit .................................................................................................................... 34
5.2 VALIDITY OF THEORITICAL ANALYSIS.......................................................... 35
4.2.1 Manufacturing .................................................................................................... 35
4.2.2 Product Testing .................................................................................................. 36
CHAPTER 4 RESULT AND DISCUSSION .......................................................................... 37
5.1 RESULT .................................................................................................................... 37
4.2.1 FLEXIBLE HOSE.............................................................................................. 38
4.2.2 TESTING ........................................................................................................... 38
5.2 DISCUSSION............................................................................................................ 41
4.2.1 AIR CONDITIONER REPAIRED COMPONENTS........................................ 41
4.2.2 DECORATION DESIGN .................................................................................. 43
4.2.3 EASY TO SETUP.............................................................................................. 44
CHAPTER 5 CONCLUSION AND RECOMMENDATION................................................. 45
5.1 CONCLUSION ......................................................................................................... 45
5.2 FUTURE DEVELOPMENT ..................................................................................... 46
REFERENCES......................................................................................................................... 47
APPENDIX .............................................................................................................................. 48

10
CHAPTER 1: INTRODUCTION
1.1. Portable Air Conditioning system
Portable air conditioner is an innovation product originally from standard air
conditioner that is limited to be used in room or inside building . Then, it is design to
make it easier to move from one place to another. This product is design looks like a
decoration tree which people mostly use it as an decoration in outdoor event such as
wedding and talk.
As we all notice that Malaysia has a tropical rainforest climate due to its
proximity to the equator. It is hot and humid country all year round, with an average
temperature of 27 °C (80.6 °F) and almost no variability in the yearly temperature.
Mostly malaysians are finding a way to get comfort escpecially during day event. This
portable air conditioner can help them to produce comfortable environment in the hot
day. Besides, they do not have to depend to conventional fan that still producing warm
air but this portable will give cold air same as normal air conditioner that in close
room.
This portable air conditioner is equiped with photo sensor that can sense the
existence of people in front of it and it will automatically switch off if there is no
people and it will turn on back if it detect people crossing or standing in front of it.
This will make people easier rather than switching on or off manually especially in the
busy event. It is also economize the electricity when the usage is continously without
people using it which lead to waste the energy.
The present of air conditioner is difficult to install especially to fit in outdoor
environment. This product is design with wheel which make it easier to move and
install. With the simplest installation procedure, anyone can easily install the air
conditioner to wherever they are desired.

11
1.2. Statement Of Problem
Nowadays, air conditioners are commonly found in homes and in public
enclosed spaces due to the natural demand for thermal comfort.the air conditioner has
become an important thing in providing comfortable due to hot temperature climate
especially in south east asia countries. Because of that, they need an alternative way to
encounter the hot day especially in outdoor event.
But right now, lack of air conditioner has been produced for outdoor usage and
because of that there are some difficulties to set up the normal air conditioner to be
used in the open space which is required a lot of time to spend to move and set up the
air conditioner.
Concerning into this problem, I have found there is a high demand to a product
which solving this problem and make people easier to transfer from one place to
another which is saving in term of time and cost.
Besides that, during outdoor event the air conditioner should has suitable space
to place in order to get full air condition function which is located as near to
participant of the event and it should not bother the decoration of the event. To solve
this case, the air conditioner should be looks like a part of the event decoration such as
decoration tree.

12
1.3. Objective
1. To develop a new type of portable air conditioning system which is
easy to setup and bring everywhere rather than conventional air
conditioner.
2. To design a new design of air conditioner that can reduce space
which can be used as decoration.
3. To repair a broken air conditioner to be working and produce a new
type of air conditioner.
1.4. Scope And Limitation
After a discussion about this project, I have set up a few limitations that must
be attention for this project. The air conditioner should place near and direct to people
in order to get full function of the air conditioner. And user needs provide power
supply to plug in the electricity to the air conditioner.

13
CHAPTER 2: LITERATURE REVIEW
5.1A Short History Of Refrigerant-Cycle Air Conditioners
Remarkably, one of our founding fathers, Ben Franklin, had a hand in the
underlying science of air conditioning. In 1758, Ben Franklin and a colleague in
England, chemist John Hadley, conducted an experiment on the cooling properties of
evaporation. By using a bellows to evaporate highly volatile liquids like alcohol and
ether, they were able to drop the temperature to 7°F, building up a thick layer of ice on
their mercury thermometer—while the ambient temperature was 64°F (Energy
Solution, 2012)
In 1820, another of history‘s greatest scientists, the British inventor Michael
Faraday, showed that by mechanically compressing ammonia to liquefy (condense) it
and then allowing the ammonia to expand and evaporate, he could cool air. And in
1842, a Florida physician, John Gorrie, wanting to keep patients cool, was able to use
this principal to make ice in an Apalachicola hospital. Gorrie patented his system in
1851 and hoped to commercialize it to cool buildings, but his financial backer died
and with it, Gorrie‘s path to success. Air conditioning would not reappear for 50 years
(Energy Solution, 2012).
In 1902, Willis Carrier of Syracuse, New York perfected a system for
dehumidifying a commercial printing plant. The goal was to stabilize the paper, but
the invention also kept the plant‘s temperature more comfortable and the workers
more productive. He formed The Carrier Air Conditioning Company of America to
produce these systems, eventually extending beyond commercial buildings to homes.
With 32,000 employees in 170 countries, Carrier Corporation(now a subsidiary of
United Technologies Corporation) is today the world leader in high-technology
heating, air conditioning, and refrigeration systems (Energy Solution, 2012).

14
5.2 General Air Conditioning System
A fan draws air from the room first through a cooling device, consisting of
metal fins extending from a pipe through which cooling fluid circulates, at a rate
determined by the thermostat or by the humidistat. The air next passes over a heater,
usually electrical, which is energised on instructions from the room thermostat.
FIGURE 1- Minimal Air Conditioning.
The part of the system in the room, on the left, pulls airfirst over a cool surface
and then over a warming surface. The part of the system on the right recirculates the
cooling fluid. The fluid passes from the reservoir through a valve B into the lower
pressure within the cooling unit in the room. There the liquid boils, removing heat
from the air. The boiling point is fixed by the constant pressure set by valve A. The
vapour is then compressed and condensed back into a liquid which collects in the
reservoir ready for another cycle.

15
Air conditioning has in the past been used where the climate is too hot for
comfort. Cooling will increase the relative humidity of the air, so humidification is not
usually built into these systems. If it is necessary, the usual method is to inject steam
from electrically boiled water. That is all there is to the part of the system in the room,
which is sketched on the left in figure The bit that is more difficult to understand, or at
least unfamiliar to most people, is how the cooling fluid is produced and controlled.
That is the part on the right of the diagram.
The cooling fluid used to be a chlorofluorocarbon compound, and often still is,
though they all more or less ravage the earth's ozone layer. The essential
characteristics of these fluids is that they have quite a low boiling point at atmospheric
pressure and that they can stay in the pipes for a long time without decomposing either
themselves or the pipes. Finally they need to have some lubricating ability, or the
ability to carry a lubricant, because the fluid has to be compressed and pumped round
the system. This rare set of necessary properties has proved difficult to combine with
friendliness to the earth's atmosphere. The liquid is let into the cooling unit through a
valve marked B on the diagram. It evaporates while it passes through the pipe, taking
heat from the air just as water evaporating from a towel laid on your fevered brow
cools you when on holiday in the Mediterranean.
The temperature in the cooling coil depends partly on the amount of fluid let
in by the valve, which is controlled by the thermostat or the humidistat. But now
comes a crucial difference from your Mediterranean experience: the minimum
temperature at the cold surface can be fixed by controlling the pressure in the cooling
coil, with the valve marked A on the diagram. The boiling point of any liquid depends
on the pressure. One could use water in the cooling coil, if the pressure is kept low
enough. At 1000 Pa pressure, which seems a lot but is just 1% of atmospheric
pressure, water boils at 7 degrees. It isn't used in cooling coils of this evaporative type
because it has practical disadvantages.

16
The reason for wanting to limit the minimum temperature is to stop ice clogging the
air passage. There are clever systems which notice when ice has formed and hold a
melting pause, but that adds to the cost. The pressure controller is therefore set to
make the cooling fluid boil at the lowest temperature that is likely to be needed to
control the humidity, but always over zero degrees. The temperature needed for
cooling is nearly always higher than that needed for dehumidification so it is the RH
setting that is decisive.
This brings me to the first point that conservators need to understand: it is expensive to
produce air at a dew point below about 4 degrees in this type of equipment. This
dewpoint corresponds to 50% RH at 15°C. This sort of air conditioning is entirely
suitable for keeping people comfortable but it is not good for specialised stores, for
films or for furs, for example, where one needs a temperature below 15 degrees. Such
equipment is, however, often used for such places. A better solution is to use an
absorption dehumidifier, which will be described in a later article.
Now back to the main story: The vapour that emerges through the pressure controller
is gathered up by a compressor. The compression also heats the gas, as will be
understood by anyone who has pumped up a cycle tyre. The hot gas is then led away
from the room, to be cooled down. This is often done on the roof or in a small
enclosure which vibrates to the roar of the fan blowing air over the fins of a condenser.
The cooled, now liquid coolant is piped back to the reservoir, ready for its next tour
through the room air conditioner.
The entire process described above is inefficient and uses electricity, which is itself
produced by inefficient conversion of heat energy. Such systems are therefore
confined to small places where the inefficiency is compensated by the generally high
reliability and freedom from maintenance.

17
5.3 Air-Conditioning Processes
An air-conditioning proces (Wang, S.K. and Lavan, Z, 2009) describes the
change in thermodynamic properties of moist air between the initial and final stages of
conditioning as well as the corresponding energy and mass transfers between the moist
air and a medium, such as water, refrigerant, absorbent or adsorbent, or moist air itself.
The energy balance and conservation of mass are the two principles used for the
analysis and the calculation of the thermodynamic properties of the moist air.
Generally, for a single air-conditioning process, heat transfer or mass transfer
is positive. However, for calculations that involve several air-conditioning processes,
heat supplied to the moist air is taken as positive and heat rejected is negative.
The sensible heat ratio (SHR) of an air-conditioning process is defined as the
ratio of the change in absolute value of sensible heat to the change in absolute value of
total heat, both in Btu/hr:
Equation 1:
For any air-conditioning process, the sensible heat change
Equation 2:

18
The latent heat change is
Equation 3:
5.4Type Of Air Conditioning Systems
There are several type of air conditioning systems(J. Paul Guyer, 2009)) that
are commonly use to build up an air conditioner which are:
4.2.1 Central Air Conditioning Systems.
Use these systems for applications where several spaces with uniform loads
will be served by a single apparatus and where precision control of the environment is
required. Cooling coils can be direct expansion or chilled water. Select air cooled or
evaporative condensers, cooling towers, and ground-loop systems based on life cycle
economics considering operating efficiencies and maintenance costs associated with
outdoor design conditions and environment, e.g., high ambient temperatures and dusty
conditions could adversely impact the operation of air cooled condensers. Consider
temperature rise of chilled water supply when selecting chilled water coils, especially
for applications requiring precision humidity control.

19
4.2.2 Unitary Air Conditioning Systems.
These systems should generally be limited to loads less than 100 tons. Unitary
systems are packaged in self-contained or split configurations. Self-contained units
incorporate components for cooling or cooling and heating in one apparatus.
Thermostatic expansion valves are preferred over capillary tubes and orifices for
refrigerant control when available as a manufacturer's option since expansion valves
provide better superheat control over a wide range of operating conditions. Split
systems may include the following configurations:
a) Direct expansion coil and supply fan combined with a remote
compressor and condensing coil; or
b) Direct expansion coil, supply fan, and compressor combined with a
remote condenser, cooling tower, or ground-loop system.
These systems generally have lower first cost than central systems but may
have higher life cycle costs. If part load operation is anticipated for a majority of
equipment operating life, consider multiple unitary equipment for superior operating
efficiencies and added reliability. Refer to ASHRAE Handbook, Equipment for size
and selection criteria.
4.2.3 Room Air Conditioning Units.
These units are self-contained units serving only one space. These units are
typically referred to as window or through-the-wall type air conditioners. Rooms
served by these units should have a separate HVAC unit to provide ventilation air for a
group of rooms. Use them when they are life cycle cost effective, and in accordance
with MIL-HDBK-1190. Refer to ASHRAE Equipment Handbook.

20
4.2.4 Built-up Systems.
These systems consist of individual components assembled at the building site.
Generally, use them when a large volume of air is handled. These systems may be
used as remote air handling systems with a central cooling plant. unitary air handling
units. Determine the number of air handling units by an economic division of the load,
considering: (a) the value of space occupied by equipment; (b) the extent of ductwork
and piping; (c) the multiplicity of control, maintenance, and operating points; and (d)
energy conservation factors.
4.2.5 Split System Air Conditioners
The more common of the two types of central air conditioners, split system air
conditioners have the compressor / condenser housed in a unit outdoors and the
evaporator indoors. The primary benefit of split system air conditioners is that they
keep the noisy part outside. Split system air conditioners connect into your existing
ductwork, cooling your home evenly and quietly

21
5.5 Air Conditioning System Components
These are major parts of an air conditioner that can be use to build up the
portable airconditioner which is to manage refrigerant and move air in two directions:
indoors and outside:
1) Evaporator – to receives the liquid refrigerant
Figure 2 - Evaporator
2) Condenser - Facilitates heat transfer
Figure 3 – Condensor

22
3) Expansion Valve – to regulates refrigerant flow into the
evaporator
Figure 4 - Expension Valve
4) Compressor - a pump that pressurizes the refrigerant
Figure 5 - Compressor

23
5.6 Outdoor Design Conditions
In principle, the capacity of air-conditioning equipment should be selected to
offset or compensate for the space load so that indoor design criteria can be
maintained if the outdoor weather does not exceed the design values. Outdoor and
indoor design conditions are used to calculate the design space loads. In energy use
calculations, hour-by-hour outdoor climate data of a design day should be adopted
instead of summer and winter design values. ASHRAE Handbook 1993 Fundamentals
(Chapter 24 and 27) and Wang’s Handbook of Air Conditioning and Refrigeration
(Chapter 7) both list tables of climate conditions for the U.S. and Canada (Wang‘s
Handbook of Air Conditioning and Refrigeration - Chapter 7) based on the data from
the National Climate Data Center (NCDC), U.S. Air Force, U.S. Navy, and Canadian
Atmospheric Environment Service(ASHRAE Handbook 1993). In these tables:
• Summer design dry bulb temperature in a specific location To.s, in F, is the rounded
higher integral number of the statistically determined summer outdoor design dry bulb
temperature To.ss so that the average number of hours of occurrence of outdoor dry bulb
temperature To higher than To.ss during June, July, August, and September is less than 1,
2.5, or 5% of the total number of hours in these summer months (2928 hr). The data
are an average of 15 years. An occurrence of less than 2.5% of 2928 hr of summer
months, that is, 0.025 2928 = 73 hr, is most widely used.
• Summer outdoor mean coincident wet bulb temperature in F, is the mean of all the
wet bulb temperatures at the specific summer outdoor design dry bulb temperature To.s
during the summer months.
• Summer outdoor 2.5% design wet bulb temperature is the design wet bulb
temperature that has an average annual occurrence of less than 73 hr. This design
value is often used for evaporative cooling design.
• Mean daily range, in F, is the difference between the average daily maximum and
the average daily minimum temperature during the warmest month.

24
• In ASHRAE Handbook 1993 Fundamentals, solar heat gain factors (SHGFs), in
Btu/h.ft2, are the average solar heat gain per hour during cloudless days through
double-strength sheet (DSA) glass. The maximum SHGFs are the maximum values of
SHGFs on the 21st of each month for a specific latitude.
• Winter outdoor design dry bulb temperature To.w, in F, is the rounded lower integral
value of the statically determined winter outdoor design temperature To.ws, so that the
annual average number of hours of occurrence of outdoor temperature To > To.ws is equal
to or exceeds 99%, or 97.5% of the total number of hours in December, January, and
February (2160 hr).
A degree day is the difference between a base temperature and the mean daily outdoor
air temperature To.m for any one day, in F. The total numbers of heating degree days
HDD65 and cooling degree days CDD65 referring to a base temperature of 65F per
annum are (J. Paul Guyer, 2009)
Equation 4:

25
5.7 Motion Sensor
Motion detection(Wikipedia, the free encyclopedia) is a process of confirming a
change in position of an object relative to its surroundings or the change in the
surroundings relative to an object. This detection can be achieved by
both mechanical and electronic methods. In addition to discrete, on or off motion
detection, it can also consist of magnitude detection that can measure and quantify the
strength or speed of this motion or the object that created it. When motion detection is
accomplished by natural organisms, it is called motion perception.
Motion can be detected by: sound (acoustic sensors), opacity (optical and
infrared sensors and video image processors), geomagnetism (magnetic sensors,
magnetometers), reflection of transmitted energy (infrared laser radar, ultrasonic
sensors, and microwave radar sensors), electromagnetic induction (inductive-loop
detectors), and vibration (triboelectric, seismic, and inertia-switch sensors). Acoustic
sensors are based on: electret effect, inductive coupling, capacitive
coupling, triboelectric effect, piezoelectric effect, and fiber
optic transmission. Radar intrusion sensors have the lowest rate of false alarms.
Motion sensor is a device for motion detection. That is, it is a device that
contains a physical mechanism or electronic sensor that quantifiesmotion that can be
either integrated with or connected to other devices that alert the user of the presence
of a moving object within the field of view. They form a vital component of
comprehensive security systems, for both homes and businesses.
Motion sensor that transforms the detection of motion into an electric signal.
This can be achieved by measuring optical changes in the field of view. Most motion
detectors can detect up to 15 – 25 meters (50–80ft).

26
There are four types of sensors used in motion detectors spectrum:
1. Passive infrared sensors (Passive)-Senses body heat. No energy is
emitted from the sensor.
2. Ultrasonic (active)-Sends out pulses of ultrasonic waves and measures
the reflection off a moving object.
3. Microwave (active)-Sensor sends out microwave pulses and measures
the reflection off a moving object. Similar to a police radar gun.
4. Tomographic Detector (active)-Senses disturbances to radio waves as
they travel through an area surrounded by mesh network nodes. Has the
ability to detect through walls and obstructions.

27
5.8 Design Of Tree As Decoration
In Malaysia, mostly events are designed with tree decoration especially in
wedding because it is the symbol of traditional. There few types of tree that been used
as decoration such as oak, palm oil and christmas.
Nowadays, tree branches is a trend of the wedding decoration that will not
being out-dated. Tree is growing from a seed via hundred years, thousand years. It is a
gift from mother nature and it is a gift for wedding couple to have a memorable
wedding uniquely(aweddingplannermalaysia.blogspot.com,2012).
Tree signatures a support and strong bond with human. Tree trunk is like our
love of each other who is giving a solid supports to all the people to sit or stand under
it. When hot sun or heavy rain, the tree leaves will cover us and let us to have faith
facing challenge and continue the life journey. It symbolize a lovely meaning for
couple to use tree as their wedding decoration.
Figure 6 – Decoration Of Tree In Outdoor

28
Tree can be decorated in various way and present in different theme such as
Winter Wonderland with white cherry blossom tree, Oriental with pink cherry blossom
tree, Secret Garden with green trees, etc.Tree can be transformed in various design in a
wedding such as table centerpiece, walkway, entrance, wishing tree to hang message.
Every tree branches used in decoration are real and taken from forest.
If you are an eco-friendly supporter or go green supporter, be mindful to choose this
decoration idea.
Figure 7 – Decoration Of Tree On Stage

29
5.9 PORTABLE AIR CONDITIONER
The evolution of an industry and its impact on society often make an
interesting study. Take portable air conditioning: Introduced to America in 1983 by
Denso, a Japanese manufacturer of automotive products, portable air conditioning was
first designed to cool workers on the assembly line.
Initially distributed through the traditional air conditioning wholesale supply
channel, it achieved marginal success in the early years. American industry had little
interest in such an expensive solution, and only a handful of companies adopted this
method for worker comfort.
Most sales in those first years consisted of stock orders from the wholesaler.
Few end user orders were placed. With excess inventory in stock, wholesaler reorders
were scarce. It wasn‘t long before some adjustments needed to be made to the
distribution channel to jump start sales. The decision was made to establish a network
of direct-sales outlets that specialized in portable air conditioning and sold directly to
the marketplace.
This proved to be much more successful than traditional wholesale-
distribution. Sales to the end user improved, but it was good timing that proved to be
the most influential element to the success of the industry. That timing relates to the
explosion of the minicomputer that began in the mid 1980s, during this same period.
4.2.1 EARLY DATA ROOM
Enter the portable air conditioner (spot cooler as it has since been dubbed) as a
dedicated a/c system for many of these smaller computer rooms.
Use in the computer room created visibility and really previewed the products‘
problem-solving capabilities. Other applications for people and process cooling were
soon extrapolated from this exposure. But not all of these new applications had the
year-round requirements of the dedicated computer cooler.

30
Some of these new applications resulted from emergency a/c failures or
shutdowns. Others resulted from the higher ambient temperatures in the summer.
These shorter-term needs spawned a demand for rentals, so many of these specialty
distributors responded by developing rental fleets and a structure to provide immediate
access to their customers.
4.2.2 RENTAL MARKET
Portable air conditioning providers started setting up shop across the country.
By the mid 1990s, nearly all major and most secondary cities had a supplier in the
area.
As the market expanded, additional manufacturers with new and different
products sprang up. Units were now offered in not only air-cooled but also water-
cooled, split system, and heat pump configurations. Spot cooling was being used to
solve people-, equipment-, and process-cooling problems throughout the workplace.
Portable air conditioning was becoming mainstream.
Portable air conditioners generally refer to units on wheels that can fit through
standard interior doorways. As such, they can be deployed anywhere within a
commercial building. This tends to limit portable air conditioners to about 5 tons in
capacity. Mobile air conditioners are units mounted on trailers or skids, which can be
hauled or trucked to a site. Mobile units can be anything from a 10-ton trailer-mounted
unit, to 1,000-ton chillers on flat beds.
As the portable air conditioning market was expanding, the mobile air
conditioning market was also growing. American business was becoming increasingly
reliant upon instant access to cooling for any number of cooling problems, large or
small. While portables were ideal for isolated cooling issues within a commercial or
institutional building, mobile units could be dispatched to provide cooling for entire
buildings or structures. Often, both were used for providing the cooling solution.

31
4.2.3 CONTRACTOR SOLUTIONS
Air conditioning and mechanical contractors became the biggest advocates for
portable air conditioners. Uses vary depending on conditions. Most contractors rent
equipment, as the larger portable a/c providers will inventory all types and models
locally, making renting a viable option.
Some contractors also maintain a small fleet of the more popular models for
quick deployment. Among the most popular applications are rentals for interim
cooling when replacing, repairing, or servicing server or computer room air
conditioning units. Many contractors also specify portables as dedicated cooling units
for a variety of long-term cooling needs.
But the end user also found spot cooling to be the ideal way to provide
equipment protection as well as worker comfort. Customers in industries across the
entire spectrum have utilized portables in the office, warehouse, production area, or on
the construction site. It‘s safe to say there aren‘t many, if any, types of business that
haven‘t used portables to solve heat-related issues.
Companies with multiple locations or national platforms have become
particularly frequent users as heat-related problems at one location often are also
experienced at others. It is quite common to provide the same products or services to
different branches of nationwide companies across the country. For the same reason,
national service companies also utilize portables regularly.
When something solves your problem, you come to rely on it. Use it often
enough, and it is no longer considered a luxury, but a necessity. Take it away, and you
experience hardship. You would find this to be true if you no longer had access to
your cell phone, laptop, or the Internet.
Add portable air conditioning to this list. It has evolved to the point where it is
no longer just a curiosity; from our standpoint, it ranks in importance right up there
with all of our other modern conveniences.

32
CHAPTER 3 METHODOLOGY
Methodology can properly refer to the theoretical analysis of the methods
appropriate to a field of study or to the body of methods and principles particular to a
branch of knowledge(www.answers.com/topic/methodology). In this chapter, it talks
about the methods use to gather information in order to finish the research. It was
involve the process flow of every step in archive the objective of this project. There
are many methods use in this project such as internet references, interviewing lecturers
and technicians and the most important is group discussion.
METHODOLOGY
Internet
Design Analysis
Group Discussion
Product Testing
Manufacturing
Visit
Validity of Theoretical
Analysis
Theoretical
Analysis

33
5.1 THEORETICAL ANALYSIS
4.2.1 Group Discussion
There 2 more students with same that are doing research on the same type of
project which is air conditioner but 2 of them are doing in different part. So, we are
also gather together to discuss about this project,. By discussing among the group, we
help each other to solve problem. By doing group discussion we manage to came out
with a few solution of the problem statement. These are the discussion that we were
discussed:
4.2.2 Final year project topic.
To complete the requirement of this final year project, I need to choose three topic to
be our own project and we have come out with few topics which need further
discussion to select which topic are the suitable. The 3 topics are compressor study,
refrigerant study and I have finally decided to choose new generation of portable air
conditioner as the topic of my final year project. We have concluded that they will do
their test also in my project. This is because the new generation of portable air
conditioner has full fill all the final year project requirement that are application,
realistic, modification and innovation.
4.2.3 Time frame of the project.
At first stage, we have discussed the time line of this project. After the topic
was selected, we were writing the topic proposal for one week. We had divided into
four phases of the time frame. For the first phases, we had searched as many as
information that could for about two month. The second phases are we start writing
the progress report. The progress report included introduction, literature review and
methodology. We spent time for this phase about two months. Phase three and four
will be next semester which the manufacturing process and result.

34
4.2.4 Risk and analysis of this project successfully.
In our project, i have found few risks that can jeopardise my result. So i discuss
with them. The risks that we face are the process of manufacturing needs highly skill.
Manufacturing the portable air conditioner involve process such as safety, assembling,
and painting. If there are mistake happen, the functionality of this air conditioner will
be reduce. Other than that, to develop the portable air conditioner we need to spend a
lot of money to make this project success. So we have set up a few limitations on our
project to get good result.
4.2.5 Internet
By using the internet, I manage to get useful information about components to
construct the portable air conditioner that I can choose which the suitable components
can be equipped to the portable air conditioner. From the internet I have found the
common decoration that people are using especially for Malaysians.
4.2.6 Design Analysis
After gather all information, I need to design portable air conditioner. At the
early stage I only do drawing and sketching on the paper. I have drawn as many
designs that possible. After complete the drawing, we have chosen one drawing that is
the best design and the latest. The next step is to get the measurement of the design
that can be suit into air conditioning system.
4.2.7 Visit
I have been set up to visit Giat Mara Teluk Intan which they have won
innovation competition among Giat Mara Malaysia with innovation airconditioner
product. The purpose to come here is to get some advice about the air conditioning
system from their teacher and use some of their facilities to manufact the air
conditioner due to Unikl Miat is not have enough tools and equipment especially for
normal air conditioner.

35
5.2 VALIDITY OF THEORITICAL ANALYSIS
4.2.1 Manufacturing
Before starts the manufaturing process, there are some materials are needed to
prepared to manufact this smart portable air conditioner which are:-
1. Hose
2. Fiber
3. Resin
4. Wheels
5. Paint
6. Decoration stuff
7. Refrigerant (R22 and Co2)
Beside that, the list equipments needed on this project are:-
1. spanar set
2. solder and welder
3. filler
4. brush
5. thermometer
6. drill
7. vacuum pump
8. pressure gauge

36
In the manufacturing process, I have chosen all the suitable components to use
in the system then assemble all of it to be a air conditioning system. The decoration of
the portable airconditioner will be making as housing of the conditioner. There are
severeal steps in manufacturing process which are:-
1. Finding unused components whether already damaged or still working
but it should be repairable. The main components should find is
compressor and blower.
2. The next step is repair the components. There are several steps of
repairing process such as placing parts, welding, soldering and wiring.
The problem that usually occur on the unused compressor and blower is
leakage at the pipes.
3. The air conditioner is design raftly and it should be fitted wih the
components then do the scaling to get the exact size of the air
conditioner body.
4. Then it is proceed with molding the the air conditoner body by using
composite materials. The materials used to build the air conditioner
body are fiber, resin and catalyst.
5. After the bulding the body is finished, it is proceed with the painting
process. The body is paint by using varnish to make it look like a real
tree. then it will add some decorations like leaf.
6. The last stage of the process is testing. The product is tested by
assembling all the components and connect with the power source.
4.2.2 Product Testing
After the product has been finalized, this product will be tested in Unikl Miat
workshop. it will test the portable air conditioner to use inside the workshop whether it
can operate or not. If not, some modification should do to make sure it functions
properly.

37
CHAPTER 4 RESULT AND DISCUSSION
5.1 RESULT
To create smart portable air conditioner, the components of the air conditioner
that will be used has been identify to suit with the design. It has been done by finding
unused components of air conditioner such as blower and compressor. The data was
collected.
Figure 8 – Final Product Of Smart Portable Airconditioner

38
4.2.1 FLEXIBLE HOSE
Flexible wire is use on this smart portable air conditioner system because it is
easier to move the air conditioner rather than using cooper tube. The flexible hose is
made of rubber and it is usually uses in car air conditioning system. For this this
system, I have been using this hose for 10ft but we can increase the length of the hose
if need.
Figure 9 - Flexible Hose
4.2.2 TESTING
The testing of this smart portable air conditioner has been tested at two type of
place which are in small confined place ad outdoor. The thermometer has been used to
measure the temperature. It was put 1meter in front of the air conditioner direct to the
air out. This test is done to measure the effectiveness of the air conditioner to cool the
environment.

39
Time (Minute) Temperature (Degree
Celcius) at 6x8x4ft room
Temperature (Degree
Celcius) atoutdoor in
open air
1
34 36
2
32 36
3
30 35
5
28 33
10
25 32
20
25 32
Table 1- Result of the test
As we can see from the result, the air conditioner is easier to cool in the small
confined room because of the closed area. But in the open area, this is very difficult to
cool because of the some reason which are it was placed in open air and the blower
was not strong for cooled air to reach longer distance. The blower should be strong as
a big fan to cool larger area.

40
Distance (feet)
Temperature (Degree Celcius) in small
confined room
0
25
0.5
25
1
25
1.5
27
2
28
2.5
29
3
30
Table 2 – Distance the cold air can travel
Based on the result above, the maximum distance of the cold air can travel is 2
feet which is the optimum distance effectiveness of the portable air conditioner. It is
still not reaching the target in the beginning of the project. This should be improved in
the future with adding a stronger blower which can increase the distance of the cold air
travel.

41
5.2DISCUSSION
4.2.1 AIR CONDITIONER REPAIRED COMPONENTS
The old type of window air conditioner is choose because of the size of the
component is small and easy to be suited to the design which is tree. The component is
use as blower of the smart portable air conditioner.
Figure 10 - Blower of Broken Window Airconditioner
Then, I found a damaged compressor but it still repairable because of the motor
is still working properly.
Figure 11- Originally of Broken Compressor

42
For the repaired, I have been doing repairing on the compressor and the
blower. For the blower, there are some leakage found on the copper pipe but the I have
soldered all the leakage. To make sure there is no leakage, the pipe have been tested
by using water and soap.
On the compressor part, there are some problem on the wiring which is the
wired broken and it may caused by rat or wire decayed. New set of wiring has been
installed on this compressor.
In the other side, by using the repaired components of the air conditing system
has been reducing the cost of making the project which the price of the components
were sold in low price.
In market view, we can just selling this product cheaper in the market place
compared to other portable air conditioners that already established in the market.
Beside that, we might able to recycle the broken components instead of the
components become waste.

43
4.2.2 DECORATION DESIGN
The smart portable air conditioner has been design to look like a decoration
tree. It has been made from composite and painted in brown which look like a real
tree. The tree is suitable to be used as a decoration.
Figure 12 - Composite Body Of Portable Airconditioner
So that, there is no needs a larger area to place air conditioner especially during
event. We can also place the smart portable air conditioner directly to cool the area.

44
4.2.3 EASY TO SETUP
The smart portable air conditioner has been equipped with wheels which make
it easier to move rather than lift it up with the heavy compressor. The weight of their
air conditioner blower also has been reduced due to the body was ade of composite
which is light weight and strong.
Beside that, it has been designed with ‗plug and on‘ concept which we just
needed to plug the power source to switch on this system. Other than that, there are
just a few steps to assemble the system. It is also could make us faster to install the air
conditioner system rather than conventional air conditioner system.
Figure 13 - Design of The Smart Portable Air Conditioner

45
CHAPTER 5 CONCLUSION AND RECOMMENDATION
5.1 CONCLUSION
As a conclusion, we can conclude that a cheap portable air conditioner is
achievable and can be marketable in reality. The portable air conditioner made
satisfies the basic air conditioner functions for cooling purpose. The air conditioner
has been tested to its functions and realibility of its design.
Human factor taught us that human may feel comfortable because of several
factors. One of the factor is the temperature, as we all noticed that some of the country
especially country with equatorial climate such as south east asia have hot temperature
climate. Because of that, air conditioner become one of the important thing that help
people to feel comfortable with reducing temperature in their sorrounding. We can
conclude that this smart portable air is marketable.
With the decoration design such as tree is the frequent that been used in
Malaysia during events. It is because it shows the concept of nature and many people
the concept. But then, mostly event such as on stage has very limited space to place
air conditioner. So, this smart portable air conditioner is possible to reduce space for
air conditioner with placing in decorations space which is near to the user.
The smart portable air condtioner is also proved that it is making people easier
to move the air condtioner with the wheels and simple assembling system. It could
make user faster to move and setup the air conditioner.

46
5.2 FUTURE DEVELOPMENT
As this is the first stage of development. Some of the ideas is still can not be
applied on this project because of some problems and time limitation. So that, I will
leave it for the other stage of development either for my own project or other student.
There are a few things that can be improvised this portable air conditioner in the future
develepment.
The electrical energy consumed can be reduced by setting the smart portable
air conditioner to operate automatically. This can be simply done by placing motion
sensor that can sense the motion of people and turn the power on then it will of when
there is no people in that area.
Besides that, other improvement that can be made on this project is to increase
the strength of the cold air flow with creating a new design with adding more or
replce high power of blower. The high power of blower can produce strong air flow
which can increase the length distance.

47
REFERENCES
i. Energy Solution,buildinggreen.com,
http://www2.buildinggreen.com/blogs/chilling-out-air-conditioners
ii. Wang, S.K. and Lavan, Z. ―Air-Conditioning and Refrigeration‖ Mechanical
Engineering Handbook, 2009
iii. J. Paul Guyer, 2009,Introduction to Air Conditioning Systems
iv. Wang‘s Handbook of Air Conditioning and Refrigeration (Chapter 7)
v. ASHRAE Handbook 1993 Fundamentals (Chapter 24 and 27)
vi. Wikipedia, the free encyclopedia,
http://en.wikipedia.org/wiki/Motion_detection
vii. A Wedding Planner MalaysiaBlog,
http://aweddingplannermalaysia.blogspot.com/2012/09/tree-branches-wedding-
decoration-idea.html
viii. http://www.answers.com/topic/methodology

Design and fabrication of smart portable air conditioner

More Related Content

What's hot

Viewers also liked

Similar to Design and fabrication of smart portable air conditioner

Recently uploaded

Design and fabrication of smart portable air conditioner